U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD...

70
DOE/NASA CONTRACTOR REPORT DOE/NASA CR-150693 PROTOTYPE SOLAR HEATING AND COMBINED HEATING AND COOLING SYSTEMS (QUARTERLY REPORT NO. 5) Prepared by General Elkctric Company - Space Division ,Post Office Box 8661 Pjjiladelphia, Pennsylvania 19101 Under Contract NAS8-32092 with National Aeronautics and Space Administration George C. Marshall Space Flight Center, Alabama 35812 For the U.S. Department of Energy 4JUN 1878 RE'm VED (NAS--CR-150693) fROTOflEE S01AD HEATING N78-25542 AND COCBIED HEATING AND COOLING SYSTEMS lQuarterly Report, Jul. 1977 - Sep. 1977 IZGeneral Electric Co.) 69 p EC A04/HF A01 Unclas CSCL i0A G3/44 21372 U.S. Department of Energy Solar Energy @ C https://ntrs.nasa.gov/search.jsp?R=19780017599 2018-06-01T12:51:31+00:00Z

Transcript of U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD...

Page 1: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

DOENASA CONTRACTOR REPORT

DOENASA CR-150693

PROTOTYPE SOLAR HEATING AND COMBINED HEATING AND COOLING SYSTEMS (QUARTERLY REPORT NO 5) Prepared by

General Elkctric Company - Space Division Post Office Box 8661 Pjjiladelphia Pennsylvania 19101

Under Contract NAS8-32092 with

National Aeronautics and Space Administration George CMarshall Space Flight Center Alabama 35812

For the U S Department of Energy

4JUN 1878

REm VED

(NAS--CR-150693) fROTOflEE S01AD HEATING N78-25542 AND COCBIED HEATING AND COOLING SYSTEMS lQuarterly Report Jul 1977 - Sep 1977 IZGeneral Electric Co) 69 p EC A04HF A01 Unclas

CSCL i0A G344 21372

US Department of Energy

Solar Energy

C

httpsntrsnasagovsearchjspR=19780017599 2018-06-01T125131+0000Z

NOTICE

This report was prepared to document work sponsored by the United States Government Neither the United States nor its agents the United States Department of Energy the United States National Aeronautics and Space Administration nor any federal employees nor any of their contractors subcontractors or their employees make any warranty express or implied or assume any legal liability or responsibility for the accuracy completeness or usefulness of any information apparatus product or process disclosed or represent that its use would not infringe privately owned rights

TECHNICAL REPORT STANDARD TITLE PAGE I REPORT NO 2 GOVERNMENT ACCESSION NO 3 RECIPIENTS CATALOG NO DOENASA CR-150693

4 TITLE AND SUBTITLE 5 REPORT DATE

October 3 1977 Prototype Solar Heating and Combined Heating and Cooling 6 PERFORMINGORGAN ZATION CODE Systems (Quarterly Report No 5)

7 AUTHOR(S) S PERFORMING ORGANIZATION REPORr

9 PERFORMING ORGANIZATION NAME AND ADDRESS 10 WORK UNIT NO

General Electric Company - Space Division P 0 Box 8661 11 CONTRACT OR GRANT NO Philadelphia Pennsylvania 19101 NAS8-32092

13 TYPE OF REPOR amp PERIOD COVERED 12 SPONSORING AGENCY NAME AND ADDRESS Contractor Report

National Aeronautics and Space Administration July 77 - Sep 77Washington D C 20546

D4 SPONSORING AGENCY CODE

15 SUPPLEMENTARY NOTES

This work was accomplished under the technical management of Mr William L Moore George C Marshall Space Flight Center Alabama

16 ABSTRACT

The General Electric Company is developing eight prototype solar heating and combined heating and cooling systems This effort includes developmentmanufacture test installation maintenance problem resolution and performance evaluation

All cost data have been removed from this report

17 KEV WORDS I1 DISTRIBUTION STATEMENT

Unclassified - Unlimited

19 SECURITY CLASSIP (of this report)

Unclassified

MSFO-Form 3292 (Rev December 1972)

WILLIAM A BROOKSBANK JR Manager Solar Heating amp Colling Pfoject Ofc

20 SECURITY CLASSIF (of this Pge) 21 NO OF PAGES 22 PRICE

Unclassified 70 NTIS

For sale by National Techmcal Information Service Spnngfield Virgima 22151

TABLE OF CONTENTS

SECTION Pae

INTRODUCTION vvi

PART I - SUMMARY 11 Cost (This p4r~graph has been deleted) 1-1 12 Schedule 1-1 13 Technical Performance 1-4 14 Variances 1-6

PART II - COST (This section has been deleted) 2-1

PART III - SCHEDULES 3-1

PART IV - TECHNICAL PERFORMANCE

Task 11 - Management 4-1 11 Program Directions (WBS 111) 4-1 12 Program Planning and Control (WBS 112) 4-4

121 Program Control 4-4 122 Data Management 4-4 123 Change Control 4- 6

13 Quality Assurance (WBS 113) 4-8

2 Task 12 - System Development 4-9 21 Introduction 4-9 22 Analysis and Integration (WBS 121) 4-9

221 Baseline System Configurations 4-9 222 System Trade Studies 4-9

2221 Collector Configuration 4-9 2222 Heat Pump Ambient Temperature Response 4- 10 2223 Energy Savings and Economics of a Solar HC System 4- 10

23 System Development (WBS 122) 4- 16 231 Heating Systems (WBS 1221) 4- 16

2311 Collectors (WBS 12211) 4- 16 23111 Collector Design and Performance

Verification 4- 16 23112 Collector Integration 4- 17 23113 Primary Heat Dump 4- 19

2312 Energy Storage 4- 19 2313 Space Heating amp Cooling 4- 19 2314 Auxiliary Energy Systems 4- 19 2315 Hot Water System 4- 19 2316 Energy Transport Subsystem 4- 19

iii

2317 Controls Subsystem bull 4-20 2318 Electrical Subsystem 4-23 2319 System Integration 4-2n

232 Hedting and Cooling Systems 4-23

2321 Collectors (TC-101) 4-23 2322 thru

2326 Ancillary Components 4-31 2327 Controls Subsystem 4-32 2328 Electrical Subsystem 4-34 2329 System Integration 4-34 23210 Cooling Subsystem (WBS 122211) 4-35

24 TEST 4-47

3 Task 13 - Deliverable Hardware 4-48

4 Task 14 - Operational Test Sites 4-49 41 Site Identification - 449 42 Site Design 4-52

421 Activity Summary 4-52 422 Normal Illinois HSF-2 4-52 423 Milwaukee Wisconsin HCOM- 4-52 424 Spokane Washington HC024-2 4-53

iv

INTRODUCTION

The Quarterly Status Report (Data Requirements Item No 500-10) provides a shy

summary of the cost schedule and technical progress of the program Since

it includes and extends the information included in the Monthly Status Reports

(Data Requirements Item No 500-11) it also meets the contract requirement

of a monthly status report It is supplemented by the financial status report

(Data Requirements Item No 500-27) submitted under separate cover

The report format is

Part I - Summary

Part II - Cost

Part III - Schedules

Part IV - Technical Performance

The report is integrated with the program management systems being used on

the program so where possible multiple use of program data such as schedules

or financial status reports has been accomplished

vvi

PART I

SUMMARY

11 COST

This paragraph has been deleted

12 SCHEDULE

The working program schedule is posted on the walls of the Program Control

Room and is used to monitor program status at daily standup meetings

Reviews with GE management are held in the Control Room to take advantage of

the detail schedule data base A summary schedule is shown in Figure 1-1

Definition of the Operational Test Sites is a continuing schedule problem

Prototype design reviews have been rescheduled and rescoped to adapt to the

number and dates of the identified sites A mini-design review was held for

the two commercial heating Operational Test Sites

Testing was an important factor this period The important collector perforshy

mance verification test was initiated but performance problems occurred which

1-1

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIP

FIELD TEST

1

1976

2113 141 12

1977

3 4

1978

112 314 1

-A

1979

2 3 4

HEATING amp COOLING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIPA

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION

SOLAR COOLING TEST

TC-00 rA TC-1O1 A

C)

COIPONENT

SUBSYSTEM

SYSTEM

MO

MOD T

lIRE

t-

Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

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-- 4

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

It MGMT

AjIII DIRECTION

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wA 122 DEVELOPMENTsr njmL---

ItI

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1 3 HARDWARE PR F SH IIP SHIP

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3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

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107G 1377 07S IVs-0 N D J F MAM_S0 N1 ) F M A M JIJ S I AIS I JIFIMIAIM JJI ODEWLORIET PLANT- -shy

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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18 15shy

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DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

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1

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12 I

14 --- I ___

16 __ I_____

18 __ __

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3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-2 SYSTEM SCHEMATIC

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amp flYWVCAAPOPRACAICCS SURMACS V

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fC)+ reg Diagnostic Instrumentation-CE r-

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 2: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

NOTICE

This report was prepared to document work sponsored by the United States Government Neither the United States nor its agents the United States Department of Energy the United States National Aeronautics and Space Administration nor any federal employees nor any of their contractors subcontractors or their employees make any warranty express or implied or assume any legal liability or responsibility for the accuracy completeness or usefulness of any information apparatus product or process disclosed or represent that its use would not infringe privately owned rights

TECHNICAL REPORT STANDARD TITLE PAGE I REPORT NO 2 GOVERNMENT ACCESSION NO 3 RECIPIENTS CATALOG NO DOENASA CR-150693

4 TITLE AND SUBTITLE 5 REPORT DATE

October 3 1977 Prototype Solar Heating and Combined Heating and Cooling 6 PERFORMINGORGAN ZATION CODE Systems (Quarterly Report No 5)

7 AUTHOR(S) S PERFORMING ORGANIZATION REPORr

9 PERFORMING ORGANIZATION NAME AND ADDRESS 10 WORK UNIT NO

General Electric Company - Space Division P 0 Box 8661 11 CONTRACT OR GRANT NO Philadelphia Pennsylvania 19101 NAS8-32092

13 TYPE OF REPOR amp PERIOD COVERED 12 SPONSORING AGENCY NAME AND ADDRESS Contractor Report

National Aeronautics and Space Administration July 77 - Sep 77Washington D C 20546

D4 SPONSORING AGENCY CODE

15 SUPPLEMENTARY NOTES

This work was accomplished under the technical management of Mr William L Moore George C Marshall Space Flight Center Alabama

16 ABSTRACT

The General Electric Company is developing eight prototype solar heating and combined heating and cooling systems This effort includes developmentmanufacture test installation maintenance problem resolution and performance evaluation

All cost data have been removed from this report

17 KEV WORDS I1 DISTRIBUTION STATEMENT

Unclassified - Unlimited

19 SECURITY CLASSIP (of this report)

Unclassified

MSFO-Form 3292 (Rev December 1972)

WILLIAM A BROOKSBANK JR Manager Solar Heating amp Colling Pfoject Ofc

20 SECURITY CLASSIF (of this Pge) 21 NO OF PAGES 22 PRICE

Unclassified 70 NTIS

For sale by National Techmcal Information Service Spnngfield Virgima 22151

TABLE OF CONTENTS

SECTION Pae

INTRODUCTION vvi

PART I - SUMMARY 11 Cost (This p4r~graph has been deleted) 1-1 12 Schedule 1-1 13 Technical Performance 1-4 14 Variances 1-6

PART II - COST (This section has been deleted) 2-1

PART III - SCHEDULES 3-1

PART IV - TECHNICAL PERFORMANCE

Task 11 - Management 4-1 11 Program Directions (WBS 111) 4-1 12 Program Planning and Control (WBS 112) 4-4

121 Program Control 4-4 122 Data Management 4-4 123 Change Control 4- 6

13 Quality Assurance (WBS 113) 4-8

2 Task 12 - System Development 4-9 21 Introduction 4-9 22 Analysis and Integration (WBS 121) 4-9

221 Baseline System Configurations 4-9 222 System Trade Studies 4-9

2221 Collector Configuration 4-9 2222 Heat Pump Ambient Temperature Response 4- 10 2223 Energy Savings and Economics of a Solar HC System 4- 10

23 System Development (WBS 122) 4- 16 231 Heating Systems (WBS 1221) 4- 16

2311 Collectors (WBS 12211) 4- 16 23111 Collector Design and Performance

Verification 4- 16 23112 Collector Integration 4- 17 23113 Primary Heat Dump 4- 19

2312 Energy Storage 4- 19 2313 Space Heating amp Cooling 4- 19 2314 Auxiliary Energy Systems 4- 19 2315 Hot Water System 4- 19 2316 Energy Transport Subsystem 4- 19

iii

2317 Controls Subsystem bull 4-20 2318 Electrical Subsystem 4-23 2319 System Integration 4-2n

232 Hedting and Cooling Systems 4-23

2321 Collectors (TC-101) 4-23 2322 thru

2326 Ancillary Components 4-31 2327 Controls Subsystem 4-32 2328 Electrical Subsystem 4-34 2329 System Integration 4-34 23210 Cooling Subsystem (WBS 122211) 4-35

24 TEST 4-47

3 Task 13 - Deliverable Hardware 4-48

4 Task 14 - Operational Test Sites 4-49 41 Site Identification - 449 42 Site Design 4-52

421 Activity Summary 4-52 422 Normal Illinois HSF-2 4-52 423 Milwaukee Wisconsin HCOM- 4-52 424 Spokane Washington HC024-2 4-53

iv

INTRODUCTION

The Quarterly Status Report (Data Requirements Item No 500-10) provides a shy

summary of the cost schedule and technical progress of the program Since

it includes and extends the information included in the Monthly Status Reports

(Data Requirements Item No 500-11) it also meets the contract requirement

of a monthly status report It is supplemented by the financial status report

(Data Requirements Item No 500-27) submitted under separate cover

The report format is

Part I - Summary

Part II - Cost

Part III - Schedules

Part IV - Technical Performance

The report is integrated with the program management systems being used on

the program so where possible multiple use of program data such as schedules

or financial status reports has been accomplished

vvi

PART I

SUMMARY

11 COST

This paragraph has been deleted

12 SCHEDULE

The working program schedule is posted on the walls of the Program Control

Room and is used to monitor program status at daily standup meetings

Reviews with GE management are held in the Control Room to take advantage of

the detail schedule data base A summary schedule is shown in Figure 1-1

Definition of the Operational Test Sites is a continuing schedule problem

Prototype design reviews have been rescheduled and rescoped to adapt to the

number and dates of the identified sites A mini-design review was held for

the two commercial heating Operational Test Sites

Testing was an important factor this period The important collector perforshy

mance verification test was initiated but performance problems occurred which

1-1

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIP

FIELD TEST

1

1976

2113 141 12

1977

3 4

1978

112 314 1

-A

1979

2 3 4

HEATING amp COOLING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIPA

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION

SOLAR COOLING TEST

TC-00 rA TC-1O1 A

C)

COIPONENT

SUBSYSTEM

SYSTEM

MO

MOD T

lIRE

t-

Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

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-- 4

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

It MGMT

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3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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SINGLE FAMILY RESIDENCE

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25

20

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___ __ _ __ - _ ___ --shy

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18 15shy

25

20

12

EERNOM

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04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

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20

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-

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= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

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3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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6

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I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205

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41- 4L7

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Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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amp flYWVCAAPOPRACAICCS SURMACS V

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 3: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

TECHNICAL REPORT STANDARD TITLE PAGE I REPORT NO 2 GOVERNMENT ACCESSION NO 3 RECIPIENTS CATALOG NO DOENASA CR-150693

4 TITLE AND SUBTITLE 5 REPORT DATE

October 3 1977 Prototype Solar Heating and Combined Heating and Cooling 6 PERFORMINGORGAN ZATION CODE Systems (Quarterly Report No 5)

7 AUTHOR(S) S PERFORMING ORGANIZATION REPORr

9 PERFORMING ORGANIZATION NAME AND ADDRESS 10 WORK UNIT NO

General Electric Company - Space Division P 0 Box 8661 11 CONTRACT OR GRANT NO Philadelphia Pennsylvania 19101 NAS8-32092

13 TYPE OF REPOR amp PERIOD COVERED 12 SPONSORING AGENCY NAME AND ADDRESS Contractor Report

National Aeronautics and Space Administration July 77 - Sep 77Washington D C 20546

D4 SPONSORING AGENCY CODE

15 SUPPLEMENTARY NOTES

This work was accomplished under the technical management of Mr William L Moore George C Marshall Space Flight Center Alabama

16 ABSTRACT

The General Electric Company is developing eight prototype solar heating and combined heating and cooling systems This effort includes developmentmanufacture test installation maintenance problem resolution and performance evaluation

All cost data have been removed from this report

17 KEV WORDS I1 DISTRIBUTION STATEMENT

Unclassified - Unlimited

19 SECURITY CLASSIP (of this report)

Unclassified

MSFO-Form 3292 (Rev December 1972)

WILLIAM A BROOKSBANK JR Manager Solar Heating amp Colling Pfoject Ofc

20 SECURITY CLASSIF (of this Pge) 21 NO OF PAGES 22 PRICE

Unclassified 70 NTIS

For sale by National Techmcal Information Service Spnngfield Virgima 22151

TABLE OF CONTENTS

SECTION Pae

INTRODUCTION vvi

PART I - SUMMARY 11 Cost (This p4r~graph has been deleted) 1-1 12 Schedule 1-1 13 Technical Performance 1-4 14 Variances 1-6

PART II - COST (This section has been deleted) 2-1

PART III - SCHEDULES 3-1

PART IV - TECHNICAL PERFORMANCE

Task 11 - Management 4-1 11 Program Directions (WBS 111) 4-1 12 Program Planning and Control (WBS 112) 4-4

121 Program Control 4-4 122 Data Management 4-4 123 Change Control 4- 6

13 Quality Assurance (WBS 113) 4-8

2 Task 12 - System Development 4-9 21 Introduction 4-9 22 Analysis and Integration (WBS 121) 4-9

221 Baseline System Configurations 4-9 222 System Trade Studies 4-9

2221 Collector Configuration 4-9 2222 Heat Pump Ambient Temperature Response 4- 10 2223 Energy Savings and Economics of a Solar HC System 4- 10

23 System Development (WBS 122) 4- 16 231 Heating Systems (WBS 1221) 4- 16

2311 Collectors (WBS 12211) 4- 16 23111 Collector Design and Performance

Verification 4- 16 23112 Collector Integration 4- 17 23113 Primary Heat Dump 4- 19

2312 Energy Storage 4- 19 2313 Space Heating amp Cooling 4- 19 2314 Auxiliary Energy Systems 4- 19 2315 Hot Water System 4- 19 2316 Energy Transport Subsystem 4- 19

iii

2317 Controls Subsystem bull 4-20 2318 Electrical Subsystem 4-23 2319 System Integration 4-2n

232 Hedting and Cooling Systems 4-23

2321 Collectors (TC-101) 4-23 2322 thru

2326 Ancillary Components 4-31 2327 Controls Subsystem 4-32 2328 Electrical Subsystem 4-34 2329 System Integration 4-34 23210 Cooling Subsystem (WBS 122211) 4-35

24 TEST 4-47

3 Task 13 - Deliverable Hardware 4-48

4 Task 14 - Operational Test Sites 4-49 41 Site Identification - 449 42 Site Design 4-52

421 Activity Summary 4-52 422 Normal Illinois HSF-2 4-52 423 Milwaukee Wisconsin HCOM- 4-52 424 Spokane Washington HC024-2 4-53

iv

INTRODUCTION

The Quarterly Status Report (Data Requirements Item No 500-10) provides a shy

summary of the cost schedule and technical progress of the program Since

it includes and extends the information included in the Monthly Status Reports

(Data Requirements Item No 500-11) it also meets the contract requirement

of a monthly status report It is supplemented by the financial status report

(Data Requirements Item No 500-27) submitted under separate cover

The report format is

Part I - Summary

Part II - Cost

Part III - Schedules

Part IV - Technical Performance

The report is integrated with the program management systems being used on

the program so where possible multiple use of program data such as schedules

or financial status reports has been accomplished

vvi

PART I

SUMMARY

11 COST

This paragraph has been deleted

12 SCHEDULE

The working program schedule is posted on the walls of the Program Control

Room and is used to monitor program status at daily standup meetings

Reviews with GE management are held in the Control Room to take advantage of

the detail schedule data base A summary schedule is shown in Figure 1-1

Definition of the Operational Test Sites is a continuing schedule problem

Prototype design reviews have been rescheduled and rescoped to adapt to the

number and dates of the identified sites A mini-design review was held for

the two commercial heating Operational Test Sites

Testing was an important factor this period The important collector perforshy

mance verification test was initiated but performance problems occurred which

1-1

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIP

FIELD TEST

1

1976

2113 141 12

1977

3 4

1978

112 314 1

-A

1979

2 3 4

HEATING amp COOLING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIPA

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION

SOLAR COOLING TEST

TC-00 rA TC-1O1 A

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COIPONENT

SUBSYSTEM

SYSTEM

MO

MOD T

lIRE

t-

Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

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-- 4

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

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131 SYSTEM 1 PDR FAR COMMERCIAL

3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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SINGLE FAMILY RESIDENCE

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___ __ _ __ - _ ___ --shy

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18 15shy

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12

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DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

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-

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= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

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3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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I o 12 I

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t Ai

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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025rIs - 978 2056 t-O A+ AS t m l - 1 I f R T ASemA ( FOR

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FS CI CT3 CE4 - Control Sensors

fC)+ reg Diagnostic Instrumentation-CE r-

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 4: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

TABLE OF CONTENTS

SECTION Pae

INTRODUCTION vvi

PART I - SUMMARY 11 Cost (This p4r~graph has been deleted) 1-1 12 Schedule 1-1 13 Technical Performance 1-4 14 Variances 1-6

PART II - COST (This section has been deleted) 2-1

PART III - SCHEDULES 3-1

PART IV - TECHNICAL PERFORMANCE

Task 11 - Management 4-1 11 Program Directions (WBS 111) 4-1 12 Program Planning and Control (WBS 112) 4-4

121 Program Control 4-4 122 Data Management 4-4 123 Change Control 4- 6

13 Quality Assurance (WBS 113) 4-8

2 Task 12 - System Development 4-9 21 Introduction 4-9 22 Analysis and Integration (WBS 121) 4-9

221 Baseline System Configurations 4-9 222 System Trade Studies 4-9

2221 Collector Configuration 4-9 2222 Heat Pump Ambient Temperature Response 4- 10 2223 Energy Savings and Economics of a Solar HC System 4- 10

23 System Development (WBS 122) 4- 16 231 Heating Systems (WBS 1221) 4- 16

2311 Collectors (WBS 12211) 4- 16 23111 Collector Design and Performance

Verification 4- 16 23112 Collector Integration 4- 17 23113 Primary Heat Dump 4- 19

2312 Energy Storage 4- 19 2313 Space Heating amp Cooling 4- 19 2314 Auxiliary Energy Systems 4- 19 2315 Hot Water System 4- 19 2316 Energy Transport Subsystem 4- 19

iii

2317 Controls Subsystem bull 4-20 2318 Electrical Subsystem 4-23 2319 System Integration 4-2n

232 Hedting and Cooling Systems 4-23

2321 Collectors (TC-101) 4-23 2322 thru

2326 Ancillary Components 4-31 2327 Controls Subsystem 4-32 2328 Electrical Subsystem 4-34 2329 System Integration 4-34 23210 Cooling Subsystem (WBS 122211) 4-35

24 TEST 4-47

3 Task 13 - Deliverable Hardware 4-48

4 Task 14 - Operational Test Sites 4-49 41 Site Identification - 449 42 Site Design 4-52

421 Activity Summary 4-52 422 Normal Illinois HSF-2 4-52 423 Milwaukee Wisconsin HCOM- 4-52 424 Spokane Washington HC024-2 4-53

iv

INTRODUCTION

The Quarterly Status Report (Data Requirements Item No 500-10) provides a shy

summary of the cost schedule and technical progress of the program Since

it includes and extends the information included in the Monthly Status Reports

(Data Requirements Item No 500-11) it also meets the contract requirement

of a monthly status report It is supplemented by the financial status report

(Data Requirements Item No 500-27) submitted under separate cover

The report format is

Part I - Summary

Part II - Cost

Part III - Schedules

Part IV - Technical Performance

The report is integrated with the program management systems being used on

the program so where possible multiple use of program data such as schedules

or financial status reports has been accomplished

vvi

PART I

SUMMARY

11 COST

This paragraph has been deleted

12 SCHEDULE

The working program schedule is posted on the walls of the Program Control

Room and is used to monitor program status at daily standup meetings

Reviews with GE management are held in the Control Room to take advantage of

the detail schedule data base A summary schedule is shown in Figure 1-1

Definition of the Operational Test Sites is a continuing schedule problem

Prototype design reviews have been rescheduled and rescoped to adapt to the

number and dates of the identified sites A mini-design review was held for

the two commercial heating Operational Test Sites

Testing was an important factor this period The important collector perforshy

mance verification test was initiated but performance problems occurred which

1-1

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIP

FIELD TEST

1

1976

2113 141 12

1977

3 4

1978

112 314 1

-A

1979

2 3 4

HEATING amp COOLING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIPA

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION

SOLAR COOLING TEST

TC-00 rA TC-1O1 A

C)

COIPONENT

SUBSYSTEM

SYSTEM

MO

MOD T

lIRE

t-

Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

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-- 4

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

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1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

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20

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___ __ _ __ - _ ___ --shy

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18 15shy

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12

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1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

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20

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POp

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50

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EERs

-

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= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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I o 12 I

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t Ai

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 5: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

2317 Controls Subsystem bull 4-20 2318 Electrical Subsystem 4-23 2319 System Integration 4-2n

232 Hedting and Cooling Systems 4-23

2321 Collectors (TC-101) 4-23 2322 thru

2326 Ancillary Components 4-31 2327 Controls Subsystem 4-32 2328 Electrical Subsystem 4-34 2329 System Integration 4-34 23210 Cooling Subsystem (WBS 122211) 4-35

24 TEST 4-47

3 Task 13 - Deliverable Hardware 4-48

4 Task 14 - Operational Test Sites 4-49 41 Site Identification - 449 42 Site Design 4-52

421 Activity Summary 4-52 422 Normal Illinois HSF-2 4-52 423 Milwaukee Wisconsin HCOM- 4-52 424 Spokane Washington HC024-2 4-53

iv

INTRODUCTION

The Quarterly Status Report (Data Requirements Item No 500-10) provides a shy

summary of the cost schedule and technical progress of the program Since

it includes and extends the information included in the Monthly Status Reports

(Data Requirements Item No 500-11) it also meets the contract requirement

of a monthly status report It is supplemented by the financial status report

(Data Requirements Item No 500-27) submitted under separate cover

The report format is

Part I - Summary

Part II - Cost

Part III - Schedules

Part IV - Technical Performance

The report is integrated with the program management systems being used on

the program so where possible multiple use of program data such as schedules

or financial status reports has been accomplished

vvi

PART I

SUMMARY

11 COST

This paragraph has been deleted

12 SCHEDULE

The working program schedule is posted on the walls of the Program Control

Room and is used to monitor program status at daily standup meetings

Reviews with GE management are held in the Control Room to take advantage of

the detail schedule data base A summary schedule is shown in Figure 1-1

Definition of the Operational Test Sites is a continuing schedule problem

Prototype design reviews have been rescheduled and rescoped to adapt to the

number and dates of the identified sites A mini-design review was held for

the two commercial heating Operational Test Sites

Testing was an important factor this period The important collector perforshy

mance verification test was initiated but performance problems occurred which

1-1

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIP

FIELD TEST

1

1976

2113 141 12

1977

3 4

1978

112 314 1

-A

1979

2 3 4

HEATING amp COOLING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIPA

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION

SOLAR COOLING TEST

TC-00 rA TC-1O1 A

C)

COIPONENT

SUBSYSTEM

SYSTEM

MO

MOD T

lIRE

t-

Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

O

-- 4

gt

17lt

T aw

0

S

mVU 0

EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

It MGMT

AjIII DIRECTION

QI T U 4 b-6 A

11I3 ASSURANCE- _ -CUST- -_ C DELTA

FO----R PF PDR FAR SHIP DEVELOPMENT I IPIFR DR12 ANALYSIS amp - A A I

2 SYSTEM S SPDR

wA 122 DEVELOPMENTsr njmL---

ItI

H IC-- _ DELIVERALE

1 3 HARDWARE PR F SH IIP SHIP

131 SYSTEM 1 PDR FAR COMMERCIAL

3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

0C110CUEROa STATUS D A(URL

107G 1377 07S IVs-0 N D J F MAM_S0 N1 ) F M A M JIJ S I AIS I JIFIMIAIM JJI ODEWLORIET PLANT- -shy

2 VER IF[CATION PLAN A

[2QtTYSUACE PLAN - - -

4SVSTI RF30VfiCE SPECIFICATION 5 SOURCE ANDSPECCOITROL DRAtVINGS

6 CItA-GE PROPOSALAh ASSOCIATEDPLAN

I F-ELIARY DESIGNREVIEWDATA

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SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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SINGLE FAMILY RESIDENCE

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___ __ _ __ - _ ___ --shy

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18 15shy

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12

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04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

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1z 40 - E s 24 4

5

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= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

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3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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t Ai

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

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Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 6: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

INTRODUCTION

The Quarterly Status Report (Data Requirements Item No 500-10) provides a shy

summary of the cost schedule and technical progress of the program Since

it includes and extends the information included in the Monthly Status Reports

(Data Requirements Item No 500-11) it also meets the contract requirement

of a monthly status report It is supplemented by the financial status report

(Data Requirements Item No 500-27) submitted under separate cover

The report format is

Part I - Summary

Part II - Cost

Part III - Schedules

Part IV - Technical Performance

The report is integrated with the program management systems being used on

the program so where possible multiple use of program data such as schedules

or financial status reports has been accomplished

vvi

PART I

SUMMARY

11 COST

This paragraph has been deleted

12 SCHEDULE

The working program schedule is posted on the walls of the Program Control

Room and is used to monitor program status at daily standup meetings

Reviews with GE management are held in the Control Room to take advantage of

the detail schedule data base A summary schedule is shown in Figure 1-1

Definition of the Operational Test Sites is a continuing schedule problem

Prototype design reviews have been rescheduled and rescoped to adapt to the

number and dates of the identified sites A mini-design review was held for

the two commercial heating Operational Test Sites

Testing was an important factor this period The important collector perforshy

mance verification test was initiated but performance problems occurred which

1-1

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIP

FIELD TEST

1

1976

2113 141 12

1977

3 4

1978

112 314 1

-A

1979

2 3 4

HEATING amp COOLING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIPA

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION

SOLAR COOLING TEST

TC-00 rA TC-1O1 A

C)

COIPONENT

SUBSYSTEM

SYSTEM

MO

MOD T

lIRE

t-

Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

O

-- 4

gt

17lt

T aw

0

S

mVU 0

EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

It MGMT

AjIII DIRECTION

QI T U 4 b-6 A

11I3 ASSURANCE- _ -CUST- -_ C DELTA

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wA 122 DEVELOPMENTsr njmL---

ItI

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1 3 HARDWARE PR F SH IIP SHIP

131 SYSTEM 1 PDR FAR COMMERCIAL

3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

0C110CUEROa STATUS D A(URL

107G 1377 07S IVs-0 N D J F MAM_S0 N1 ) F M A M JIJ S I AIS I JIFIMIAIM JJI ODEWLORIET PLANT- -shy

2 VER IF[CATION PLAN A

[2QtTYSUACE PLAN - - -

4SVSTI RF30VfiCE SPECIFICATION 5 SOURCE ANDSPECCOITROL DRAtVINGS

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

COAtUA AtI PIOCRAMAUVISOA SBkRO

RCGRAIIS AOA0ON 1OCS RIJNK clm -ARCWpARSJGIMRAN MAOIR[

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

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25

20

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___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

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6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 7: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

PART I

SUMMARY

11 COST

This paragraph has been deleted

12 SCHEDULE

The working program schedule is posted on the walls of the Program Control

Room and is used to monitor program status at daily standup meetings

Reviews with GE management are held in the Control Room to take advantage of

the detail schedule data base A summary schedule is shown in Figure 1-1

Definition of the Operational Test Sites is a continuing schedule problem

Prototype design reviews have been rescheduled and rescoped to adapt to the

number and dates of the identified sites A mini-design review was held for

the two commercial heating Operational Test Sites

Testing was an important factor this period The important collector perforshy

mance verification test was initiated but performance problems occurred which

1-1

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIP

FIELD TEST

1

1976

2113 141 12

1977

3 4

1978

112 314 1

-A

1979

2 3 4

HEATING amp COOLING SYSTEMS

DEVELOPMENT

QUALIFICATION

FAB amp SHIPA

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION

SOLAR COOLING TEST

TC-00 rA TC-1O1 A

C)

COIPONENT

SUBSYSTEM

SYSTEM

MO

MOD T

lIRE

t-

Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

O

-- 4

gt

17lt

T aw

0

S

mVU 0

EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

It MGMT

AjIII DIRECTION

QI T U 4 b-6 A

11I3 ASSURANCE- _ -CUST- -_ C DELTA

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wA 122 DEVELOPMENTsr njmL---

ItI

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1 3 HARDWARE PR F SH IIP SHIP

131 SYSTEM 1 PDR FAR COMMERCIAL

3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

0C110CUEROa STATUS D A(URL

107G 1377 07S IVs-0 N D J F MAM_S0 N1 ) F M A M JIJ S I AIS I JIFIMIAIM JJI ODEWLORIET PLANT- -shy

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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amp flYWVCAAPOPRACAICCS SURMACS V

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fC)+ reg Diagnostic Instrumentation-CE r-

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 8: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

UAT Kys Plarred CCoplctlonA ktual Completion

Planned A Actual Slippage

MASTER PROGRAM PLAN NEW

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HEATING SYSTEMS

DEVELOPMENT

QUALIFICATION

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1976

2113 141 12

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HEATING amp COOLING SYSTEMS

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Figure 1-1 Master Prograur-Plan

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

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HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

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FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

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Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

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Figure 3-2 WBS Element Schedule and Status

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SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

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Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

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DESIGN POINT COPTH (A)

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DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

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SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 9: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

make a retest mandatory The horizontal TES tank design was verified by test

The solar integrator vendor ran into problems in qualification testing and

some redesign of this component will be required

Hardware delivery of the collector shrouds is a schedule limiting item for the

test site hardware Because of technical problems production has not started

13 TECHNICAL PERFORMANCE

13 1 PROGRAM 4ANAGEM2ENT

Program direction continued per plan Highlights of the period were the program

redirection meetings with NASA and ERDA the submission of the redirection

change proposal and the prototype design review for the commercial heating

sites

132 DEVELOPMENT

System analysis activity this period was directed toward prediction of the

performance of the prototype systems and trade studies for the design of the

modified cooling subsystem Analytical models of the TC-101 solar collector

were generated and used to predict the performance of configuration candidates

A significant result of the analysis was an improved understanding of the imshy

portance of EER in system performance and economics

The solar collector verification tests were initiated and a performance problem

was discovered This is attributed to the selective coating and a task force

is investigating the reasons for the problem prior to initiating production of

TC-100 shrouds

Designs were completed for the two commercial heating prototype systems (Milwaukee

and Spokane) Hardware lists were prepared A revised list of sensors for the

Normal site was generated at an integration meeting with IBA

1-3

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

O

-- 4

gt

17lt

T aw

0

S

mVU 0

EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

It MGMT

AjIII DIRECTION

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11I3 ASSURANCE- _ -CUST- -_ C DELTA

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1 3 HARDWARE PR F SH IIP SHIP

131 SYSTEM 1 PDR FAR COMMERCIAL

3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

0C110CUEROa STATUS D A(URL

107G 1377 07S IVs-0 N D J F MAM_S0 N1 ) F M A M JIJ S I AIS I JIFIMIAIM JJI ODEWLORIET PLANT- -shy

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

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25

20

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___ __ _ __ - _ ___ --shy

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18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

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20

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50

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EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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2 _____

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6

Figure 23-1

I o 12 I

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t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 10: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

Preliminary studies indicate the impact of the higher temperatures and pressures

in the redirected solar cooling system on the design of ancillary components

will be small

A major activity in this task was the preliminary design of the redirected

cooling subsystem designated HRE Fluid performance studies were carried out

with the recommended fluids being FC-188 in the Rankine engine and R-114 in

the heat pump subsystem Configuration and performance studies resulted in

the recommended configuration of a unitary expander - rotary compressor shy

motor unit The system will utilize two compatible fluids with a shaft seal

between them to avoid the penalties associated with a single fluid system

Preliminary designs were prepared for the system elements including the controls

133 DELIVERABLES

Hardware procurement for the Normal OTS proceeded during this period Items

are being accumulated for the First Article Review which is scheduled early

in the next reporting period Items not on hand at the end of this period

included the solar collector shrouds solar integrator energy management module

and a few smaller hardware items

Approval to order equipment for the Milwaukee and Spokane test sites was reshy

ceived at the Prototype Design Review and the ordering process has been initiated

Long lead items such as the TES tank were ordered with NASA approval prior to

the PDR

134 OPERATIONAL TEST SITE

OTS activity focused on the Normal Milwaukee and Spokane sites AampE activity

was initiated A bid package was issued to candidates for ins alling the

Normal Illinois system

1-4

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

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3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

0C110CUEROa STATUS D A(URL

107G 1377 07S IVs-0 N D J F MAM_S0 N1 ) F M A M JIJ S I AIS I JIFIMIAIM JJI ODEWLORIET PLANT- -shy

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

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___ __ _ __ - _ ___ --shy

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18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

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-

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= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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2 _____

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6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 11: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

The late identification of sites has resulted in a revised schedule for the

prototype delivery and installation

14 VARIANCES

Requested variance data is summarized in Table 1-2

1-5

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

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HEATING SYSTEMS

DEVELOPMENT amp

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HEATING amp COOLING SYSTEMS

DEVELOPMENT A

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COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

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Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

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1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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SINGLE FAMILY RESIDENCE

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___ __ _ __ - _ ___ --shy

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18 15shy

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12

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1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

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20

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50

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-

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= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

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3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

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-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 12: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

PART I I

COST

This section has been deleted

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

O

-- 4

gt

17lt

T aw

0

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

JJA S 0 N O J F M A M J J A S 0 NJO 1 2 3 4 1 2 3 4

It MGMT

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3 3 TBLDG SYSTEM

1 3 4 HARDWARE7

OPERATIONALH 1 4 TEST I IH 1 41 INSTALLATION

Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

0C110CUEROa STATUS D A(URL

107G 1377 07S IVs-0 N D J F MAM_S0 N1 ) F M A M JIJ S I AIS I JIFIMIAIM JJI ODEWLORIET PLANT- -shy

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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A GRAFRVOGRAMAANAGLR K IIADISI UItUl V

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SPACESYSlMS OlAfYlR IAlC W DJAUOR N A IOIIINLAI AI MAAIAR IDAM

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

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0 I b H 1 DWl

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9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

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MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 13: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

PART III

SCHEDULES

Summary program schedules are shown in Figures 3-1 3-2 and 3-3 These schedule

data are extracted from the detailed program working schedules posted in the

Control Room at Valley Forge

Figure 3-1 is the summary key events schedule Significant scheduled customer

events included a prototype design review for heating systems HCOM I - Milwaukee

and HCOM 2 - Spokane

Key activities in the solar array area were the completion of the shroud breakage

failure investigation and the initiation of a coating problem investigation as a

result of low performance during verification testing

Redirection of the solar cooling portion of the program resulted in a reschedule

for the cooling development activities The delivery date was dilayed to provide

time for the development of equipment to meet the redirected design requirements

The three ton unit in the originally proposed configuration was assembled and is

being checked out Expander performance tests continued

Equipment for the first residential heating system was ordered and many items reshy

ceived Solar integrators were received from ZIA and a unit placed on the outdoor

test stand The horizontal configuration TES tank was received and tested to assure

satisfactory performance Installation plans are being prepared

Design of the heating systems for two commercial operational test sites was completed

and the Prototype Design Review was held Long lead items were ordered and following

the PDR the ordering process was started for the remaining equipment

3-1

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

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EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

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HEATING amp COOLING SYSTEMS

DEVELOPMENT A

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COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

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Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

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Hl _HCTEST

1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

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___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

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POp

60

50

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EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-2 SYSTEM SCHEMATIC

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amp flYWVCAAPOPRACAICCS SURMACS V

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 14: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

Figure 3-2 is the schedule for the WBS elements The activity associated with

the heating and cooling systems has been rescheduled

F-igure 3-3 shows the data deliveries During this period all scheduled software

deliveries were completed except the new Technology Report which is in preparation

oRIGINAL pAGE Ib OF pOOlK QUALIT

3-2

O

-- 4

gt

17lt

T aw

0

S

mVU 0

EVENT KEYS MASTER PROGRAM PLAN A Planned Completion NEW A Actual Completion0 Planned amp Actual Slippage

1976 1977 1978 1979

1 3 41 2 3 4 1 2 3 4 1 2 3 4

PROGRAM GO AHEAD

HEATING SYSTEMS

DEVELOPMENT amp

QUALIFICATION WON An

FAB amp SHIP -- _ - - - - -A

FIELD TEST A

HEATING amp COOLING SYSTEMS

DEVELOPMENT A

QUALIFICATION

FAB amp SHIP

FIELD TEST

FACILITIES

COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

COMPONENT MOD I __RE

SUBSYSTEM MOD I _

SYSTEM HE

Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

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1 42 OPERATIONS SUSTAINING

143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

TCCIIIICAL CIC N-T OPPOR S OATf REQUIREMENT UL90

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Figure 3-3 Data Requirements Status

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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FORT WORTH TEXAS

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___ __ _ __ - _ ___ --shy

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18 15shy

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12

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04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

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-

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= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

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3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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t Ai

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

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MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 15: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

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HEATING SYSTEMS

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COLLECTOR PILOT PRODUCTION IC-10O TC-l10

SOLAR COOLING TEST

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Figure 3-1 MasLer Program Plan

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

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143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

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SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 16: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

AUTH CONTR REP DATE

SCHEDULE AND STATUS 1979-19781977iATGOR176

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143 ENGINEERING

Figure 3-2 WBS Element Schedule and Status

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SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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___ __ _ __ - _ ___ --shy

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DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

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I

12 I

14 --- I ___

16 __ I_____

18 __ __

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3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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I o 12 I

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t Ai

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

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SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

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7000 -

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5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 18: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

SECTION I

TASK 11 - MAnkGEMENT

11 PROGRAM DIRECTION (WBS 111)

During this period program operation continued in the manner established during

the initial quarters The program team shown in Figure 11-1 is the same as

shown in the last quarterly report except for the following changes

1 J Hatman replaces E Ernst in the Product Davelopment Engineering assignment Mr Ernst had been acting in this role and has assigned the responsibility to Mr Hatman

2 T Duff has been added to fill the System Project Engineer assignment

As a followup to the program redirection meetings discussed in the previous report

a revised program was discussed at MSFC on 71277 It was refined and discussed

with MSFC personnel at Valley Forge on 72677 and presented to ERDA at ERDA

Headquarters on 72777 The revised program was defined in a Request for Change

Proposal from MSWC in August and a Change Proposal for the redirected program

submitted at the end of August The Change Proposal included revisions to the

Development Plan and the Verification Plan The original versions of these docushy

ments were disapproved several months after their submittal because their content

no longer matched the program (after redirection) In the interim period they

had been used as program guidelines Per NASA direction a short program summary

was submitted on 9Y1277 for use in explaining the program to the public A

meeting with NASA-MSFC and IBM was attended in Huntsville on 92777 on the subshy

ject of instrumentation with emphasis on the sensor list for the Normal Illinois

Operational Test Site

During this period three candidate sites for single family residential heating and

cooling operational test sites were visited in the DallasFort worth area Of the

sites visited the site at Southern Methodist University was considered the most

4-I

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SPACESYSlMS OlAfYlR IAlC W DJAUOR N A IOIIINLAI AI MAAIAR IDAM

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

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igrKsa2SoT POIaNT T~mPr-pvn -p

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0 I b H 1 DWl

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9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

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suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

0 C

0 I b H 1 DWl

-1

0tT Pwrseo

I4shy

9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205

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41- 4L7

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SgPAA4TCR AII LZ oN -EVISIOPI

Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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amp flYWVCAAPOPRACAICCS SURMACS V

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FS CI CT3 CE4 - Control Sensors

fC)+ reg Diagnostic Instrumentation-CE r-

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 20: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

suitable However the redirection of the program in progress at that time

precluded a firm recommendation of a site Subsequently this site was forshy

warded to ERDA as a selected site The General Electric assessment of this

site is not complete and its acceptance remains tentative at this time

4-3 O)F P(Q)

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

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25

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___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

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EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

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6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 21: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

12 PROGRAM PLANNING amp CONTROL (WBS 112)

121 PROGRAM CONTROL

The baesic program control tool being used on this program is the control room

It was used during this period to schedule key milestones and program activities

and monitor their status This control room represents the official program

cchedule against which GEs technical status and progress is-monitored The

scheduled data required for the monthly quarterly and management reports is

extracted from the control room posting The schedules in the control room

include an overall program summary with detailed task schedules on the side walls

The individual task secqions of the control room schedules are monitored and mainshy

tained by the responsible task leaders Daily program status meetings are held

to follow hardware items Problems involving interactions are identified and reshy

solved at these meetings by the assignment of action items which are posted and

monitored in the control room

In the budgets area the program was monitored on the basis of the profile preshy

sented in the first quarterly report Overall budget results are posted in the

control room and are available on a continuing basis for inspection by management

122 DATA MANAGEMENT

The scheduled data submittals completed during this period were as follows

Data Requirements No

- I Development Plan Revision I

- 2 Verification Plan Revision 2

- 7 A Preliminary uC (redirected program)

Design Review Package

- 8 Prototype Design Review Data Package (HCOM-l and HCOA-2)

4-4

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

0 C

0 I b H 1 DWl

-1

0tT Pwrseo

I4shy

9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 22: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

Data Requirements No

- 9 First Article Review Data Package (HSF-2)

-10 Quarterly Report No 4

-11 Monthly Status Reports (2)

-19 Design Data Brochhre (Application Guide) Prel

-26 Financial Management Report (2) (Monthly)

-27 Quarterly Financial Report

As of this date 15 RIDs and 11 Action Items are still outstanding from the PDRs

4-5

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

0 C

0 I b H 1 DWl

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9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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rAI LA WATOR ToaETW TAW

-TT Ta -J ct At

Tp 4CcItI4 T

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FS CI CT3 CE4 - Control Sensors

fC)+ reg Diagnostic Instrumentation-CE r-

I jIP

TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 23: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

123 CHANGE CONTROL

The status of Change Proposals is as follows

CP001 - Approved with exception of 001-6

Cr002 - Cancelled

CP003 - Ft Meade Site Design - Submitted 51276

CP004 - Multi-Family Deletion - Response to RCP-301-77-010 - Withdrawn (See CP007)

CP005 - Response to TD-001 - Instrumentation Plan - Withdrawn

CP006 - Normal Illinois Site Design and Installation - Submitted and Approved

- Revision to Collector and Cooling SS - Response to RCP-301-77-011CP007 Submitted 93177

CP008 - Milwaukee Design amp Installation - Part I in Process

ou-G63 A GE lb

4-6OEORQUAT

This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

0 C

0 I b H 1 DWl

-1

0tT Pwrseo

I4shy

9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

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This page has been deleted

4-7

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

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FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

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___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 25: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

13 QUALITY ASSURANCE (WBS 113)

With the increasing build-up of production facilities and output of TC-100

collector parts and assemblies there has been considerab-le interfacing with

Air Force Quality Assurance In addition to monitoring our inspection activity

they witnessed qualification testing of the prototype Solar Integrator hail

testing of the TC-100 collector and heating system testing of the horizontal

TES tank for Normal Illinois

Significant Quality Assurance Activities

1 The failure analysis report on breakage of TC-100 glass shrouds was

issued with scratches induced during shroud installation on fin assembly

as the most significantly contribuXing factor

2 Quality Assurance Collector Engineering and Materials-Engineering have

developed a scratch resistant coating which doubles the safety margin

over uncoated glass shrouds

3 FAR activities were conducted for the acceptance of a Single Family

Heating System to be installed at Normal Illinois

4-8

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

0 C

0 I b H 1 DWl

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9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 26: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

SECTION 2

TASK 12 - SYSTEM DEVELOPq4ENT

21 INTRODUCTION

The major program development activity this period was the analysis and preshy

liminary design activity for the cooling subsystem which resulted from the

program redirection Other activities included the setup and test of a horizontal

TES tank configuration and collector shroud evaluation Preliminary design

work was accomplished for the other portions of the solar heating and cooling

system which resulted from the program redirection including the definition of

the TC-101 solar collector

22 ANALYSIS AND INTEGRATION (WBS 121)

221 BASELINE SYSTEM CONFIGURATION

The system configuration of the heating only and heating and cooling baseline

systems has not been modified Incorporation of the higher temperature HRE

requirements will only increase the operational temperature which will only

change the rating of some components and not the configuration

222 SYSTEM TRADE STUDIES

Several system trade studies were performed during this quarter and were reported

in the Heating and Cooling Preliminary Design Data Package dated September 20 1977

Studies conducted included performance characterization of the TC-101 series

collector heat pump operational characteristics as a function of ambient cut-off

temperature and the economics of a solar heating and cooling system

2221 Collector Configuration

The higher temperature requirements of the HRE dictated usage of a cusp shaped

collector which has been designated the TC-101 series With the constraint that

the TC-100 frame be utilized system simulations were made to determine number of

4-9

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

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9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 27: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

shrouds per panel which will provide the energy at the lowest cost

- The 8 shroud system is being recommended because a 7

shroud system will require that the shroud coating be modified to withstand

stagnation conditions

2222 Heat Pump Ambient Temperature Response

The operational characteristics of the heat pump and the solar system were

examined to define the effect of different heat pump cut-off temperatures on

total system performance The heat pump was modeled such that only resistance

energy would be utilized to satisfy the space energy requirements whenever the

ambient temperature was below the set point value Results of annual solar

simulations summarized in Figure 22-2 show that the increasing of the

temperature at which only 12R heat is utilized will not significantly increase

the total energy required by the system

2223 Energy Savings and Economics of a Solar Heating and Cooling System

The energy and cost savings of a solar heating and cooling system is the differential

in energy and cost of a solar ahd conventional system System analysis using the

thermal COP of the Rankine cycle the EER of the conventional and solar systems

and the seasonal and daily billing were performed to determine the value of the

energy saved (ECE) The value is expressed as the levelized system price divided

by levelized system savings Figure 22-3 shows the representative energy savings

for a single family residence located in Fort Worth Texas and Figure 22-4

shows the ECE of this house as a function of the system COP and EER

The effect of the rate structure (Figure 22-5) will produce significant reductions

in the ECE

4-10 ORIGINAL PAGE IS OF POOR QUALTV

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

0 C

0 I b H 1 DWl

-1

0tT Pwrseo

I4shy

9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205

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Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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amp flYWVCAAPOPRACAICCS SURMACS V

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 28: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

This figure has been deleted

4-11

to

Z

3

Ivp

z0

Ishy7 T90 Ro WIr

1o 7o 10 40

igrKsa2SoT POIaNT T~mPr-pvn -p

0 C

0 I b H 1 DWl

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9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

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2 _____

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6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

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activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

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04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 30: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

9000

8000

I

= 7 0 0

7000 -

S 6000

5000

FORT WORTH TEXAS

SINGLE FAMILY RESIDENCE

EERs_

25

20

PANELS 15

___ __ _ __ - _ ___ --shy

25

18 15shy

25

20

12

EERNOM

1 I I I

04 05 06 07 08

DESIGN POINT THERMAL COP

Figure 22-3 Solar Heating and Cooling KWH Savings over a Conventional HP System

4-13

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-2 SYSTEM SCHEMATIC

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 31: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

__ __ __ __

FORT WORTH TEXAS SINGLE FAMILY RESIDENCE

8

12 PANELS

EERS_ 7

12

6 20 25

5 I I 0M4 0fi 08 10

DESIGN POINT COPTH (A)

8 PANELS EER5

1 2

7 15

20

25 6

5 __ __ __ _ _

04 06 08 10

DESIGN POINT COPTH (B)

Figure 22-4 Solar Heating and Cooling Cost per KWH Saved Over HP System

Design Point COPTH Variation

4-14 ORIGIA-L PAGE 16OFPOORl QUAL

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-2 SYSTEM SCHEMATIC

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amp flYWVCAAPOPRACAICCS SURMACS V

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 32: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

70

60

FORT WORTH DAILY

POp

1

50 2

1z 40 - E s 24 4

5

30 lt10 12 34 16 18

I

20

C) 70 WASHINGTON DC DAILY

POp

60

50

4 0 [

EERs

-

10

= 20

I

12 I

14 --- I ___

16 __ I_____

18 __ __

20

3

4

5

SUMMERWINTER RATE RATIO

Figure 22-5 Solar Heating and Cooling Cost Per KWH Saved WinterSummer Rate Ratio

4-15

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-2 SYSTEM SCHEMATIC

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amp flYWVCAAPOPRACAICCS SURMACS V

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 33: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

23 SYSTEK DEVELOPMENT (WBS 122)

231 EATING SYSTEMS (WBS 1221)

2311 Collectors (WBS 12211)

23111 Collector Design and Performance Verification

Four new performance verification units were built incorporating modifications

resulting from the glass shroud failure analysis The most significant design

change was the incorporation of a high temperature paint to the inner diameter

of the shroud The paint was found to be one of the most economical and effecshy

tive methods of the prevention of scratches Other changes included minor modishy

fications to the serpentine structure and the addition of brackets for holding

the serpentine in place during shroud insertion Design changes were also inshy

corporated in the packaging materials to keep the mating surfaces (fin and shroud

ID) as clean as poss-ible until time of actual assembly These changes included a

plastic sleeve over the fins and the encapsulation of each shroud in a sealed

polyethylene bag

The failure analysis of the glass breakage problem raised several questions and

pointed out that a technique must be developed to evaluate the input of design

and process changes on the shroud fragility Therefore a statistical technique

was developed to evaluate the effect of present and possibly future design and

process features

The first statistical experiment was designed to evaluate the effects of (a) conshy

ditioning (Lehr) the glass (b) the optical coating and its related processes

(c) the anti-scratch protection and (d) interactions between the above The

evaluation program consisted of pressure testing to failure of a representative

sample of each variable in a completely random sequence After statistically

4-16

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205

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41- 4L7

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_

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SgPAA4TCR AII LZ oN -EVISIOPI

Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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GEN ERAL ELECTRIC 9 76ZU 11K n_-b C]IUSOLLOWINGbull tsUI EAWISE SP(CIFI[D$ T shy

amp flYWVCAAPOPRACAICCS SURMACS V

025rIs - 978 2056 t-O A+ AS t m l - 1 I f R T ASemA ( FOR

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FS CI CT3 CE4 - Control Sensors

fC)+ reg Diagnostic Instrumentation-CE r-

I jIP

TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 34: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

analyzing the results the following conclusions were determined

1 There is no significant difference between Lehred and un-tehred shrouds

2 There is a highly significant difference between painted and unshypainted (anti-scratch protection) shrouds

3 There is no significant difference between replication

4 There are no significant interactions between the three factors

As a result of these tests it was decided to eliminate the need for Lehring

the glass and to incorporate the paint as an anti-scratch barrier Subsequent

to the initial experiment similar experiments have been set up and run to

evaluate different types of paints and alternate fin configuratiois

The new verification units were then placed on performance testing One unit

was shipped to Desert Sunshine Testing (DST) and two units were placed on test

at General Electric Both tests included the use of painted shrouds - only one

of 40 shrouds broke The performance results of the tests are shown in Figure 23-1

The performance results at GE and DST were consistent but were well below antishy

cipated results Since the Y intercept of the verification units fell within a

range consistent with predictions the primary culprit appeared to be the emmisshy

sivity To date at least two possible causes have been identified First oil

has been found to be evident on the coated surfaces which will raise the effecshy

tive emmissivity of the coating Second the coating on the shrouds has been

found to be semi-porous and inconsistent to a greater extent than the control

specimens Therefore the actual performance of the shroud would be less than

anticipated Both avenues are being pursued at this time to resolve and correct

the cause of poor performance

23112 Collector Integration

The majority of drawings have been completed for collector integration A bracket

scheme for mounting collectors to a flat roof has been developed The only other

4-17

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205

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41- 4L7

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SgPAA4TCR AII LZ oN -EVISIOPI

Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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GEN ERAL ELECTRIC 9 76ZU 11K n_-b C]IUSOLLOWINGbull tsUI EAWISE SP(CIFI[D$ T shy

amp flYWVCAAPOPRACAICCS SURMACS V

025rIs - 978 2056 t-O A+ AS t m l - 1 I f R T ASemA ( FOR

t 1t- osA TtA O+- +f--

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FS CI CT3 CE4 - Control Sensors

fC)+ reg Diagnostic Instrumentation-CE r-

I jIP

TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 35: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

O

--

O)amp-D--

-- -

PREDICTED - SOLAR NOON

100 DIRECT

GCE TESTS -

DST TESTS -

AGE TESTS -

-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING

-

I-JI

I Figur 2-VrfcainCletoAefrac

2 _____

-_I___ ___I

6

Figure 23-1

I o 12 I

fl TIt Verification Collector Performance

t Ai

--shy |9 0 i-

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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41- 4L7

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SgPAA4TCR AII LZ oN -EVISIOPI

Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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GEN ERAL ELECTRIC 9 76ZU 11K n_-b C]IUSOLLOWINGbull tsUI EAWISE SP(CIFI[D$ T shy

amp flYWVCAAPOPRACAICCS SURMACS V

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fC)+ reg Diagnostic Instrumentation-CE r-

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 36: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

activities in this area have included drawing cleanup and revision as experience

with the manufacture of parts dictate

23113 Primary Heat Dump

A heat dump system has been designed for a 300 collector system It consists of

a 48 diameter by 36 high stainless steel clad tank containing a copper coil

vent automatic water supply and low level indicator The design is based on

boiling off water as steam for primary loop temperature control The system

appears very attractive and a smaller revision for a 24 collector module is being

considered as an alternative to the air cooled finned heat dump

2312 Energy Storage (WBS 12212)

The Thermal Energy Storage Tank Assemblies for the Milwaukee and Spokane sites

were defined and procurement of the long lead items was initiated

2313 Space Heating and Cooling (WBS 12213)

No significant activity during the reporting period

2314 Auxiliary Energy Systems (WBS 12214)

Specification No 261A2884 Boiler was updated to reflect vendor comments

2315 Hot Water Subsystem (WaS 12215)

For the Milwaukee and Spokane sites which have large DHW usage an external

rather than in-tank units were selected These units will be procured to the

same specification as for HX-I

2316 Energy Transport Subsystem (WBS 12216)

Effort on the EM2 fabrication is continuing

4-19

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

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amp flYWVCAAPOPRACAICCS SURMACS V

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fC)+ reg Diagnostic Instrumentation-CE r-

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 37: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

2317 Controls Subsystem (WBS 12217)

23171 System Design

Two new system designs have been developed for the HCOMM sites at Milwaukee and

Spokane Major differences between these sites and the original building block

concept for Heating Commercial systems are the addition in both designs of a

flow switch in the domestic hot water loop and an additional pump in the Spokane

system to heat swimming pool water

The flow switch operates whenever hot water is drawn from the domestic hot water

tank The switch operates the storage loop pump P2 (she Figure 23-2) which transfers

collected or stored energy from the TES tank to the cold water make-up line through

heat exchanger HX- 2 In the Spokane design in addition to the flow switch conshy

trol a separate distribution loop has been added for swimming pool heating A

manual pool heating switch starts pump P4 (see Figure 23-3) provided thermal switches

Cr5 and CT6 are closed CT5 sets a minimum TES operation temperature fox pool

heating CT6 senses outdoor ambient temperature and inhibits the solar pool heating

mode when temperatures fall below 550F

23172 Component Development

231721 Sensors The first four solar integrator-units have been received

from Zia and are presently under test and review Zia has not completed its qualishy

fication testing of the units at this time

231722 System Controls The system controls package for Milwaukee and Spokane

will be fabricated by an HVAC-type controls supplier (Honeywell Barber-Colman etc)

A specification for the controls package for Milwaukee has been written a similar

specification is underway for Spokane

OrIGINAL PAGE l OF pOOR QUALITY

4-20

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41- 4L7

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SgPAA4TCR AII LZ oN -EVISIOPI

Figure 23-2 SYSTEM SCHEMATIC

~t~~ 17-0 5

-------

GEN ERAL ELECTRIC 9 76ZU 11K n_-b C]IUSOLLOWINGbull tsUI EAWISE SP(CIFI[D$ T shy

amp flYWVCAAPOPRACAICCS SURMACS V

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FS CI CT3 CE4 - Control Sensors

fC)+ reg Diagnostic Instrumentation-CE r-

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TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 38: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

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Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 39: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

-------

GEN ERAL ELECTRIC 9 76ZU 11K n_-b C]IUSOLLOWINGbull tsUI EAWISE SP(CIFI[D$ T shy

amp flYWVCAAPOPRACAICCS SURMACS V

025rIs - 978 2056 t-O A+ AS t m l - 1 I f R T ASemA ( FOR

t 1t- osA TtA O+- +f--

rAI LA WATOR ToaETW TAW

-TT Ta -J ct At

Tp 4CcItI4 T

--i- _V4Toloo aoo zUDO_ 5UF Ob-sv~ O

TA00

- AB REETAL I -2PV2 PUMP HP-

PRVZ I A FLUID IOOV BOILERTIjE -

FLLARA R~rPw

-WaOO

J 1O+ 0-- D o ---COW r TIAM c

A~ ~~8t

5S11 RATOR P2O LIOA c~ hA Li ianotc-nsruetaioJ+

FS CI CT3 CE4 - Control Sensors

fC)+ reg Diagnostic Instrumentation-CE r-

I jIP

TXXX TD)rXX WXXX EPXXX - NASA Instrumentation IWGAL

I I I

Figure 23-3 SYSTEM SCHEMATIC-

For YWCA Spokane Washington

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 40: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

2318 Electrical Subsystem

Drawing 132D6029 shows the ControlElectrical drawing for the Milwaukee site was

provided with the PDR data package A similar drawing for Spokane is currently

nearing completion

2319 System Integration (WBS 122110)

The system integration activities were concentrated toward the detailed definition

of the operational test sites The results of these activities are included in

Section 41 of this document

232 HEATING AND COOLING SYSTEMS (WBS 1222)

2321 Collector Subsystem (TC-I01) (PBS 12221)

The usage of the high temperature Rankine air conditioner requires a re-evaluation

of the TC-100 collector characteristics to ascertain the effects of higher tempershy

ature operating conditions The approach to increasing the collection efficiency

at elevated temperatures is to increase the collector concentration ratio with a

cusp-shaped reflector This new collector configuration will be designated as

Model TC-101

The TC-101 collector was modeled and coded into the GE solar simulation

code Utilizing the single family Fort Worth house to provide typical heating

and cooling loads various concentration ratios were simulated

to define their relative performance characteristics Decreased energy collecshy

tion with increased concentration ratio results from a decrease in the number of

shrouds per square foot of projected surface area and a decreased field of view

of each shroud The performance of the TC-101 collector exceeds the TC-100

collector up to a concentration ratio of 133

A constraint placed on the IC-101 collector is that the external dimensions of the

collector panel must be the same as the current TC-100 panel As such only specific

concentration ratios associated with integral numbers of shrouds are considered

4-23

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 41: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

This figure has been deleted

4-24

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 42: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

This paragraph has been deleted

The proposed system will therefore consist

of 8 shrouds per panel

The decision to increase the concentration ratio for higher temperature performance

requires the selection of high quality reflective materials with greater stability

due to the fact that the average number of reflections has increased A comprehenshy

sive review of existing reflector surfaces is in progress including the following

4-25

BLMampSampVT

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 43: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

materials

Alzak Coilzak Scotchkal 5400 Scotchkal FEK-244 Kingslux Alglas

Table 23-3 shows the selection of preferred material for various weighting factors

based on published data Inhouse testing is presently underway to verify the

reported data

4-26

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 44: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

TABLE 23-1

Obtainable Concentration Ratios with

TC-101 Collector Panel

ConcentrationNuiber of shrouds Ratio _per panel

1446

1247

10858

0979

This table has been deleted

OF p00 QU

4-27

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 45: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

This figure has been deleted

4-28

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 46: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

This figure has been deleted

4-29

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 47: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

TABLE 23-3 REFLECTOR RATING BASED ON PUBLISHED DATA

Major Reflector Material Selection Criteria

H CI

-44

0

O

a

10

bull

o

Spectral Reflectance

Salt-Fog

Formability

Availability

Cost

Repeatability

Corrosion Resistance

Self-Cleaning

Abrasion Resistance

Manufacture Ease

x

X

X

X

I

X

x

x

X

x

X

X X

X

I

X

I

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 48: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

2322 thru 2326 Ancillary Components for the Heating amp Cooling System

Since the November 1976 Preliminary Design Review a larger data base exists for

the ancillary system components Functional specifications have bebn prepared

for all the major hardware elements these specifications have been reviewed

with major suppliers revised as required and have been used to procure hardware

for the heating only systems

For the new higher temperature heating and cooling systems the specifications will

be revised There does not appear to be any major problems with new requirements

In the area of pumps both of the primary pump sources Taco and drundfos indicate

that their pumps will be able to meet the new pressure and temperature levels

Similar responses were obtained from Heat Exchanger manufacturer Durham-Bush and

the tank manufacturer Wood Industrial Products Co For the tanks the only

change will be that the ASME working pressure rating will be raised New pressure

relief valves in both the collector loop and the storage loop uprated to meet the

new working pressure levels will be required

It is therefore concluded that there will not be any major affect on the system

ancillary components as a result of the higher rated temperature and pressure

levels

4-31

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 49: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

2327 Controls Subsystem

23271 System Design

Few changes have been made in the Heating and Cooling System Controls in this

time period All of the system controls are being reassessed as to the impact

of the SEDHP change to a Hermetic Rankine Unit

232711 Single Family Heating and Cooling The only design change in this

area is the utilization of a 3 stage heating 3 stage cooling thermostat Table

23-4 shows the previous heating and cooling staging versus the new system using

the 3 stage unit There is still a 15 minute lockout of electric cooling when solar

cooling is available

232712 Commercial Heating and Cooling A change in the backup heating method

has changed the controls logic When solar energy stored in the TES tank is availshy

able (CT3 gt 120 F) a hydronic distribution loop supplies the space heating load to

all of the zones When the tank temperature is low the heat pump (SEDHP) is used

with an auxiliary backup This replaces a previous design which used a boiler in

the hydronic loop as an auxiliary energy backup

23272 Sensors

The last quarterly report described a new sensor development termed an Analog Tempershy

ature Switch which provided three temperature switch points from one nickel RTD

With the change to the Hermetic Rankine Engine the release of a request for quote

on this unit has been delayed awaiting the new higher temperature set points

4-32

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 50: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

Table 23-4 Heating and Cooling Thermostat Staging

PREVIOUS DESIGN NEW DESIGN

TES TRIP gt1270F -lt120 F p 1270 F lt120degF

HEATING STAGES

ist Solar Heat Heat Pump Solar Heat Heat Pump

2nd Heat Pump Heat Pump Heat Pump Heat Pump and and

Auxiliary Auxiliary

3rd Auxiliary Auxiliary

TES TEMP gt205degF lt95degF gt 230F lt225F

COOLING STAGES

ist Solar Electric SWITCHOVER Cooling Cooling VALVE

2nd Electric Electric Solar Electric Cooling Cooling Cooling Cooling (after 15 minutes)

3rd Electric Electric

Cooling Cooling (after 15 minutes)

ORIGINAL PAGE IS OE POOR QUA-Tly

4-33

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 51: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

2328 Electrical Subsystem

The Heating and Cooling ControlElectrical diagrams which define the electrical

services and interconnections for the 15 building blocks have been completed

2329 System Integration (WBS 122210)

No significant activity this period

4-34

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 52: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

23210 Cooling Subsystems (WBS 122211)

The following presents the status of the cooling subsystems development effort

Early in this report period a major cooling subsystems development redirection

occurred The redirected cooling subsystems include 3 ton and 10 ton capacity

split system solarelectric driven heat pumps and their associated equipment

The key design redirection included a conversion from water cooled to air cooled

condensing equipment the conversion of the 10 ton capacity design from a single

packaged cooling unit to a split system heat pump the use of hermetically sealed

expandercompressormotor assemblies the use of higher Rankine cycle operating

temperatures and the selection of higher performance potential Rankine and

refrigerant cycle fluids Model I expander development activities (designs prior

to redirection) continued through this report period with the emphasis on perforshy

mance evaluation of materials and thermal and mechanical efficiencies

232101 SubsystemAnalysis

Initial studies were conducted to identify and screen the potential working fluids

for both the Rankine and refrigeration cycles These studies indicated that R-113

R-114 R-133a and FC88 were viable candidates for the Rankine cycle with R-114

R-133a and R-22 for the refrigerant cycle In order to select an optimum system

from these candidates a detailed analysis was conducted on eachfluid This

analysis involved the generation of component operating models for the heat exchazgers

single and dual stage rotary vane expanders and rotary vane compressors These

models in conjunction with a thermodynamic cycle computer program were used to

predict the operating characteristics and performance levels of a variety of single

and dual expansion single and dual fluid systems Figure 23-7 presents

a summary of this analysis showing the predicted Rankine cycle efficiency as a

function of expander inlet pressure for the candidate fluids and single and dual

stage expanders Also included is the overall thermal COP (ie cooling outenergy

4-35

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 53: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

I 74 shyu r 7axecoot)

70 -

Ls I 13o

7 60

7 0ir

60r

U I 7 i I

R14 RG30 Z2 00 2oo o400

Trc-- -= ]I9OF 1 -JcRa-oa s

Figure 23z7- Preliminary 3-Ton Cooling PerforGance

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 54: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

into the vapor generator) for the candidate refrigerant cycle fluids

As a result of the detailed component and cycle analysis a preliminary design

point was selected for an FC88 two stage Rankine cycle coupled to a R-114

refrigerant cycle FC88 was chosen for its high level of fluid stability and

potential for performance improvements with higher collector temperatures R-114

was chosen as the heat pump fluid due to its high performance potential and

availability over R-133a Figure 23-8 presents the 3 ton cooling mode

preliminary design point cycle diagram and predicted performance

232102 HRE Heat Pump

An acronym has been formed to designate the evolution of the SEDHP The 3 ton

capacity SEDHP is designated HRE-30 (Hermetic Rankine Electric) 3 indicates

the capacity in tons and 0 indicates breadboard type hardware The 0 would become

I for qualification type hardware The 10 ton capacity SEDHP is des-ignated HRE-100

where 10 indicates capacity in tons and 0 breadboard type hardware A number of

alternate configurations for the subsystem have been evaluated The preliminary

configuration selection is shown in Figure 23-9

2321021 Expander (Model I) Performance evaluation of efficiency and material

selections continued through this report period A 200 hour endurance test was

successfully completed A peak efficiency of 68 was measured during this test

Materials evaluated included the following

Rotor - 410 Stainless Steel

Vanes - ALF-10Q TxC coated

End Plates - Ni ResistCr203 coated

Stator - Nitrided Nitralloy

Measurements of wear before and after test indicated no wear on the rotor end

plates and vanes A slight amount of wear was measured on the stator Stator

4-37

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 55: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

300 F T - 290F P - 200 PSTA Horsepower

T P

59degF 17 PSTA

T - 59F (10rSH) - 18 PSA

SI -shy - vporatorTevap -40

7G GoVe- 39400 flrua Epne Comeso M5 - 0

(95= into F17 Bc u L00 36000 Stu

T- 190F 3C P - 205 PSIAP

n 8P - 52 0

Fr11T - 1364F P -54Osc)

PPp Watts 260 2 0OItherma 0i

Figure 23-8 Two Fluid Preliminary Design Point 3-Ton Cooling Mode

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 56: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

ACCUMULATOR

SEPARATOR DESIGN BUFFER BUFFER - -95QUALITY I 290OF OIL

150 P _ SRFT SEAL

WATER -

TO RUN -- OIL FEED PUMP VAPOR- - OL ~~~~~CAPILLARY -

IL- GEN --- O-- shy

-- HEATING=-i-OIL PRESS SENSOR LGENERATO-

COILIFLOW CONTROL RAKINE OUTDOOR COliL HEAT PiuPr

DRIER _CAPILLARY PRESS RELIEF i

1 P qP PROTECTION -175_--A) FEED R-133a OR R-114 (INI ERNAL) PbLqe

Figure 2)3-9 Prelimainary ItRE Heat Pump Configuration

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 57: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

surface hardness was increased on subsequent stators with the expected improvement

measured on the wear surface Chipping was evidenced on several vane edges

Preliminary indications are that this particular set of vanes was machined on the

edges where chipping occurred subsequent to the vapor deposition process thereby

exposing a base material interface The seal assembly performed satisfactorily

through the duration of the test Several expander design modifications were also

identified as having potential to improve efficiency reliability and cost These

include the use of a smaller diameter rotor shaft thicker vanes and alternate

vane and end plate materials

2321022 Hermetic ExpanderCompressorMotor Assembly A preliminary hermetic

expandercompressormotor assembly concept is shown in Figure 23-10 -Anshy

integrated motor rotor-compressor rotor is used A clutch is provided between the

expander and compressor to decouple the expander during electric drive operation

This approach eliminates the effect of high drag losses during expander free-wheeling

and allows simplification of the expander vane pressuration and bearing lubrication

design during off-cycle operation Drag losses on the motor side were considered

tolerable (less than 1 of full load motor power) during expander drive operation

All components are hard mounted inside the pressure shell The shell is divided

into two compartments the expander space and the compressor space An absolute

seal is provided between compartments to isolate fluids by the use of a pressurized

oil buffer sealing arrangement The expander space houses the expander and clutch

The expander is a multi-vane rotary type similar to the designs used prior to the

cooling subsystem redirection It will be operated in the horizontal position The

clutch is in the selection process Clutch types being investigated include

electromagnetic disc electromagnetic tooth magnetic particle centrifugal and

overrunning To date the electromagnetic tooth clutch appears to be the leading

candidate The compressor space houses the compressor and electric motor The

compressor will be a multi-vane rotary type Bearing and vane lubrication will be

4-40

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 58: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

rOIL PRESSURE (STrAT IC)

- t -STAOE

EX PANDER icentP

BUFFERSHAFT

Figure 23-10 Preliminary Hermetic ExpanderCompressorMotor Assembly

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 59: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

provided from a refrigerant oil separator Suction gas will be used to cool the

motor windings during electric drive operation An evaluation of the various

separatord and hermetic motors has been initiated

2321023 Feed Pump A preliminary hermetically sealed feed pump assembly

concept is shown in Figure 23-11 A two-stage pumping unit design apshy

proach similar to the one described last report period will be utilized Evalushy

ation of bearings lubrication techniques and hermetic motors was initiated

232103 Heat Exchangers

There are five prime heat exchangers being evaluated for the cooling subsystem

the Rankine cycle vapor generator regenerator and condensor and the refrigerant

cycle indoor and outdoor coils Vapor generator analyses indicates a shell and

tube type heat exchanger is the leading candidate with the Rankine fluid on the

tube side and the EGH 0 on the shell side The regenerator analysis was initiated2

to evaluate what type of heat exchanger should be used The condenser analysis

indicates a plate fin configuration would be the best choice Tube size spacing

fins per inch materials and circuiting trade-off analyses were initiated The

indoor and outdoor refrigerant to air coils will be of the plate fin type for

space efficiency and low air side pressure drop

232104 Controls

The controls have been separated into three areas the system interface controls

the Rankine engine controls and the heat pump refrigerant controls Some of the

functions breadboarded in the Model I effort have application in the redirected

design Test plans are underway to evaluate these specific electronics functions

(digital timer analog temperature circuit and electrical expansion valve control)

New design efforts have begun for the electronic modulation of single phase AC

motors A triac-controlled voltage-slip design is the preferred method for low

4-42 ORIGINAL pAGE 18

OF pOOR QUAITY

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 60: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

OIL w

WERM tC -SHt-ILL

VALVE

In

4

SLEEVE

x -

INLETPROtA

COWENSOR

MampVFLUID LEVEL

CENTRIFUGNkL UP TRUSPC

Figure 23-11 Preliminary Feed Pump Assembly

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 61: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

cost motor control A breadboard of the triac system is nearing completion

A design has been started for the Rankine engine superheat control Vapor generator

water inlet temperature is compared with expander inlet temperature as a measure

of superheat When the delta temperature (AT)increases above a certain point

freon flow into the vapor generator is reduced as a control of AT A pressure

switch override located at the expander inlet assures that the inlet pressure will

not be reduced below a minimum level by the flow control Superheat is assured

by setting a minimum inlet water temperature of 2300 F

232105 Packaging

Analytical trade-offs involving the optimal sizing and arrangement of subsystem

components to achieve performance parasitic noise and cost goals were initiated

The leading outdoor section configuration concept is shown in Figure 23-12

the indoor section in Figure 23-13 Appearance design work was initiated

for the 3 ton capacity HRE heat pump outdoor section Assembly of the Model I

SEDHP prototype was completed Calibration of all key components and operational

checkout of the LTR using a throttle in lieu of the expander were performed Test

plans were generated for subsystem performance evaluation

4-44

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 62: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

t650

370

-F -

4

o

39070

I j

320

Figure 23-12 Preliminary Outdoor Section Concept 3-Ton HTR Heat Pump

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 63: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

2350 2900 REF

1006 REF

6806 REF

11975 REFL 2550 REF-

Figure 23-13 Preliminary Indoor Section 3-Ton HRE Heat Pump

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 64: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

24 Test (WBS 123)

Testing proceeded at the component subsystem and system level for 3 ton heating

and cooling configurations for the solar collectors and for the horizontal TES

tank

241 Low Temperature Rankine Component Test Loops

The LTR component test loops designated the A loops aefully opamprtional having

been checked-out and calibrated during this reporting period The 3A test stand

provides for vertical shaft orientation and the IOA test stand is-cQnfigured for

horizontal shaft mounting During the calibration and initial testing period

several instrumentation changes were made to the test loops eg in the freon

loop a rotometer flow meter was added in series with the existing turbine flow

meter to provide added data confidence and an excellent visual indication df the

freon fluid condition Other charges included matching and selecting RTD pairs

for greater accuracy also dhanged delta pressure gauges for watei flow measureshy

ments using the annubar flow sensors

242 HSF Qualification Test

The HSF qualification system was modified to incorporate the horizontal TES tank

and pumps Testing was completed and the test report issued during the reporting

period

243 Collector Testing

Performance of the verification units was measured in the VF outdoor test facility

and stagnation tests were conducted to support the investigation of the thermal coating

4-47

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 65: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

SECTION 3

TASK 13 - DELIVERABLE HARDWARE

31 NORMAL

Material was accumulated for shipment to the Normal Illinois site An area

has been set aside to array this material both for inspection purposes related

to the DD 250 and for visual display at FAR The plan is for shipment early

October 1977 immediately after FAR Shipment will be made via closed van Glass

shrouds will not be avaiiable until early November 1977 The TES tank will be

shipped with certain fittings and piping pro-assembled to the tank

32 MILWAUKEE

Following the Prototype Design Review placement of orders began on 92677 for all

Milwaukee equipment with the exception of the Lexan covers which are held pending cost

information and TC-100 shrouds The purchase order for theTES tank has been placed with

the Wood Co as an advance order item Milwaukee delivery is scheduled for late

November 1977

33 SPOKANE

Following the Prototype Design ReView placement of orders for equipment for the

Spokane site began 92677 The TC-100 shrouds are not ordered pending resolution

of problems The TES tank was advance ordered as a long lead item Hardware delshy

ivery for the Spokane site is scheduled for shipment early December The supplier

of the TES tank (Wood) is being asked to improve his December 1977 delivery date

to November 1977 If this canbe done the tank will be shipped and arrive on site

late November

OotI QJ

4-48

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 66: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

SECTION 4

TASK 14 - OPERATIONAL TEST SITES

41 SITE IDENFITICATION

Operational test activities in this period included the identification and inshy

spection of sites selected by NASAASFC Sites that have been investigated are

listed in Table 4-1 and those visited during this period are indicated with a

dash line The sites accepted are shown in Table 4-2 along with the dates of

acceptance As a part of the program redirection GE will search for suitable

sites in the Philadelphia area including GE owned facilities for one each reshy

sidential and commercial heating and cooling systems The size of the commercial

operational test site systems has been reduced to one each 10 ton unit as a part

of the redirection

4-49

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 67: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

TABLE 4-1

SITES INSPECTED BY GE

Bldg Type General City

ESP Baltimore

HCOM Muscle Shoals

Em Nashville

ESF Peoria

ESP Peoria

ESP Peoria

NME Schenectady

RMF Schenectady

M Schenectady

RCMF Chicago

ECMF Chicago

RCOM Madls n

HCOM Milwaukee

HCOM Milwaukee

ECO Milwaukee

HCOM Spokane

HCOM Spokane

HCOM Spokane

ECCOM Los Angeles

MCCOM Los Angeles

MCCOM Los Angeles

ECCOM Los Angeles

HCCOH Los Angeles

E0SF Dallas

HCSF Dallas

H|CSF Dallas

Site

7502 Young St Ft Meade MD

TVA Office at Muscle Shoals AL

Airmans Quarters AEDC Tullahoma TN

Chanute Air Force Base

MBA Champaign ILL

ISO House Normal ILL

ERA Schenectady NY

VA Hospital Staff Housing Albany

Ely Park Housing Binghamton NY

Ft Sheridan ILL

Great Lakes Naval Training Canter

Hill Farm State Office Bldg Madison WI

Washington Park Senior Citizens Center

Washington Park Community Center

Dr Martin Luther King Community Center

YWCA

East Washington State College

Community College

West LA Municipal Bldg

Dept of Water amp Power 1I

Dept of Water amp Power 02

Peck Park Rec Bldg

Police Credit Union

Presidents Home Univ of Texas at Dallas

Presidents Home N Texas State Dencon Texas

Grad Student Housing at SMU

4-50

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 68: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

TABLE 4-2

OPERATIONAL TEST SITE STATUS

DATE ACCEPTED TYPE LOCATION BY GE CaKMENTS

HSF Ft Meade Md Jan 19 1977

11SF Normal Illinois Feb 7 1977

IEMF Tullahoma Tenn Feb 7 1977 Multi-family units dropped from program verbally on April 4 and documented in minutes of April 4 meeting

IICOM Muscle Shoals Alabama Jan 19 1977 Converted to Heating and Cooling Site on 42077

HCOM Milwaukee Wisconsin May 23 1977

[COcm Open

HCSF Dallas Texas Best of DallasFt Worth sites reviewed Being reviewed for GE acceptance

HCSF Open

1UCCOM Muscle Shoals Alabama April 20 1977

JCCOM Open

L Design activity was on hold pending this decision

NOTE Great Lakes Illinois was accepted as a HCMF site on Feb 7 1977 All multLi-family sites have been dropped from the program

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 69: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

42 SITE DESIGN

421 ACTIVITY SUMMARY

Analysis of the Milwaukee Wisconsin and Spokane Washington commercial

heating only sites was completed during this period and culminated

with the Prototype Design Review held September 21 1977 Comments

on the activity of each site follow

422 NORMAL ILLINOIS HSF-2

Design analysis was completed for this site and reported at a design

review meeting held last quarter The architect has completed his

work on this project and a bid package has been sent out to

contractors in the Normal Illinois area A First Article review

is planned for the next quarter with system installation and checkout

to follow

423 MILWAUKEE WISCONSIN HIOM-l

The selected solar system for the Martin Luther King Jr Recreation

Center will consist of 300 GE TC-100 solar collector panels The

collected energy will be stored in a 2500 gallon storage tank until

needed This system will supply 10 percent of the space heating

load of 1063 MMBTUYR and 61 percent of the domestic hot water load

of 682 MMBTUYr The prototype Design Review was held at GE

Valley Forge during this reporting period An engineering firm has

been identified for this site and has started the installation

design His work is being held up at the present time waiting for

the site owner to select an architect to perform the structural

work needed on the building

4-52

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53

Page 70: U.S. Department of Energy - NASA · Under Contract NAS8-32092 with. ... TECHNICAL REPORT STANDARD TITLE PAGE . I REPORT NO. ... Solar integrators were received from ZIA and a …

424 SPOKANE WASHINGTON COM-2

A system consisting of 300 GE TC-l00 vacuum tube collector panels

has been specified for the Spokane YWCA A 6750 gallon water

storage tank will be utilized to store the collected solar energy

This solar system will provide 22 percent of the annual space load

of 1690 MMBTU and 44 percent of the 1680 MMBTU hot water requireshy

ments The not water requirements include energy required to heat

the swimming pool The prototype design review was held at the

GE Valley Forge during this reporting period An Engineering firm

has been selected to perform the installation design work and

prepare the bid package He will begin work in the next reporting

period on this design

U S GOVERNMENT PRINTING OFFICE 1978-740-193430 REGION NO 4

4-53