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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
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
EP2GTOTflPE DESIGNREVIEWVDATA
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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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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
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8000
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7000 -
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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
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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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
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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
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
EP2GTOTflPE DESIGNREVIEWVDATA
-
-
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ASREQUIRED A U R
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-
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ii2 9FIrST AITICLE flEVIEt DATA
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It I Arr fOICE TAPACKAGE
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I IPCATI0TESTANDOR~ AA SISREPORfT
I S I shy 0i I S TAL AhD MAIIT TOOL LIST
wC]prSIcTST AORAALYI PPOT----------------------------LI SI
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I 7-L OP RATIOALL NT MANUALS 13ZNALYSSt
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E REPORT
_- -A A A A A A A A
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14 _ _ _ _ _ _ _ _ _ _ _ _ _
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14 LtA
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RFOTIOYACE LTACEEVl
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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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PO tIIIO IAATMA IIOA 0ItS L SI I FAAIUIIIIAL MAhA61
SPACESYSlMS OlAfYlR IAlC W DJAUOR N A IOIIINLAI AI MAAIAR IDAM
WE NOIA oACIS a AYUIKI CLASSiNOOUCISLOI AAIM(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
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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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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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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/3.jpg)
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
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
EP2GTOTflPE DESIGNREVIEWVDATA
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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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PO tIIIO IAATMA IIOA 0ItS L SI I FAAIUIIIIAL MAhA61
SPACESYSlMS OlAfYlR IAlC W DJAUOR N A IOIIINLAI AI MAAIAR IDAM
WE NOIA oACIS a AYUIKI CLASSiNOOUCISLOI AAIM(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
Ivp
z0
Ishy7 T90 Ro WIr
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igrKsa2SoT POIaNT T~mPr-pvn -p
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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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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
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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
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
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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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6 CItA-GE PROPOSALAh ASSOCIATEDPLAN
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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[
Si RIMRPMCI PACE IIVNSIO
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PO tIIIO IAATMA IIOA 0ItS L SI I FAAIUIIIIAL MAhA61
SPACESYSlMS OlAfYlR IAlC W DJAUOR N A IOIIINLAI AI MAAIAR IDAM
WE NOIA oACIS a AYUIKI CLASSiNOOUCISLOI AAIM(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
Ivp
z0
Ishy7 T90 Ro WIr
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8000
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= 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
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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
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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
3
Ivp
z0
Ishy7 T90 Ro WIr
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igrKsa2SoT POIaNT T~mPr-pvn -p
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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
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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
EP2GTOTflPE DESIGNREVIEWVDATA
-
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I A--
ASREQUIRED A U R
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E REPORT
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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[
Si RIMRPMCI PACE IIVNSIO
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ISSTIM 0 AIIMNI I I
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PO tIIIO IAATMA IIOA 0ItS L SI I FAAIUIIIIAL MAhA61
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
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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 23-3 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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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
EP2GTOTflPE DESIGNREVIEWVDATA
-
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ii2 9FIrST AITICLE flEVIEt DATA
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I S I shy 0i I S TAL AhD MAIIT TOOL LIST
wC]prSIcTST AORAALYI PPOT----------------------------LI SI
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_- -A A A A A A A A
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14 _ _ _ _ _ _ _ _ _ _ _ _ _
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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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SPACESYSlMS OlAfYlR IAlC W DJAUOR N A IOIIINLAI AI MAAIAR IDAM
WE NOIA oACIS a AYUIKI CLASSiNOOUCISLOI AAIM(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
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
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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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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
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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
gt
17lt
T aw
0
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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
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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
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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
--
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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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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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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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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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4SVSTI RF30VfiCE SPECIFICATION 5 SOURCE ANDSPECCOITROL DRAtVINGS
6 CItA-GE PROPOSALAh ASSOCIATEDPLAN
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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
3
Ivp
z0
Ishy7 T90 Ro WIr
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I
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S 6000
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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 23-3 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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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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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
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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
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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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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wA 122 DEVELOPMENTsr njmL---
ItI
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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
3
Ivp
z0
Ishy7 T90 Ro WIr
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igrKsa2SoT POIaNT T~mPr-pvn -p
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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
CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205
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~t~~ 17-0 5
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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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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
EP2GTOTflPE DESIGNREVIEWVDATA
-
-
I A--
ASREQUIRED A U R
~ i -
LON [-I
-
A
-
PLSD
-
U
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S
I
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ii2 9FIrST AITICLE flEVIEt DATA
1 CUARIERLERI
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It I Arr fOICE TAPACKAGE
FTA -
A---
A _
A
A _A
---
A
A A A A A
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I IPCATI0TESTANDOR~ AA SISREPORfT
I S I shy 0i I S TAL AhD MAIIT TOOL LIST
wC]prSIcTST AORAALYI PPOT----------------------------LI SI
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I 7-L OP RATIOALL NT MANUALS 13ZNALYSSt
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d-R --
A A-------- --
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_-___ _ _
E REPORT
_- -A A A A A A A A
tI A A
14 _ _ _ _ _ _ _ _ _ _ _ _ _
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27~~~~~~~ ~ ~ ~ AAAA -- A-
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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
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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~t~~ 17-0 5
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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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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
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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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4SVSTI RF30VfiCE SPECIFICATION 5 SOURCE ANDSPECCOITROL DRAtVINGS
6 CItA-GE PROPOSALAh ASSOCIATEDPLAN
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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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PO tIIIO IAATMA IIOA 0ItS L SI I FAAIUIIIIAL MAhA61
SPACESYSlMS OlAfYlR IAlC W DJAUOR N A IOIIINLAI AI MAAIAR IDAM
WE NOIA oACIS a AYUIKI CLASSiNOOUCISLOI AAIM(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
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
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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 23-2 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
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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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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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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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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
I
20
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POp
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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
--
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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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Figure 23-1
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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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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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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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
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
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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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143 ENGINEERING
Figure 3-2 WBS Element Schedule and Status
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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
3
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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
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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
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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
Ivp
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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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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
Ivp
z0
Ishy7 T90 Ro WIr
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igrKsa2SoT POIaNT T~mPr-pvn -p
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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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~t~~ 17-0 5
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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
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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
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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
-~l5CYI AA7C7J co-uarYc vr4
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~~~R5
41- 4L7
__ __ DOW
-- IPrH
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_
7_T--p z
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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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
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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
-~l5CYI AA7C7J co-uarYc vr4
II F
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NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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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PRVZ I A FLUID IOOV BOILERTIjE -
FLLARA R~rPw
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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
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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
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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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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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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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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
-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
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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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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 23-2 SYSTEM SCHEMATIC
~t~~ 17-0 5
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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
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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 23-2 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
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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 23-2 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
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FORT WORTH TEXAS
SINGLE FAMILY RESIDENCE
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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
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FORT WORTH DAILY
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16 __ I_____
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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
O
--
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-- -
PREDICTED - SOLAR NOON
100 DIRECT
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AGE TESTS -
-- PREDICTED RESULTS USING LAB DEGRADATION RESULTS ON CRC COATING
-
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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
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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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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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-
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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
--
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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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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
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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
-~l5CYI AA7C7J co-uarYc vr4
II F
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~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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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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
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__ __ __ __
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
-~l5CYI AA7C7J co-uarYc vr4
II F
R3 -
- - LOADS
NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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-
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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
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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
-~l5CYI AA7C7J co-uarYc vr4
II F
R3 -
- - LOADS
NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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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FLLARA R~rPw
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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
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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
-~l5CYI AA7C7J co-uarYc vr4
II F
R3 -
- - LOADS
NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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
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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
-~l5CYI AA7C7J co-uarYc vr4
II F
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NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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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-TT Ta -J ct At
Tp 4CcItI4 T
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PRVZ I A FLUID IOOV BOILERTIjE -
FLLARA R~rPw
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J 1O+ 0-- D o ---COW r TIAM c
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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
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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
-~l5CYI AA7C7J co-uarYc vr4
II F
R3 -
- - LOADS
NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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
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- AB REETAL I -2PV2 PUMP HP-
PRVZ I A FLUID IOOV BOILERTIjE -
FLLARA R~rPw
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J 1O+ 0-- D o ---COW r TIAM c
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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
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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
CI Syte-tY ES SPC FUSETHEiFOLWNG-AATTEt + 19 7B205
-~l5CYI AA7C7J co-uarYc vr4
II F
R3 -
- - LOADS
NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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
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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
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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
-~l5CYI AA7C7J co-uarYc vr4
II F
R3 -
- - LOADS
NOR- k-ilW
~~~R5
41- 4L7
__ __ DOW
-- IPrH
7SOJ
_
7_T--p z
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
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
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- AB REETAL I -2PV2 PUMP HP-
PRVZ I A FLUID IOOV BOILERTIjE -
FLLARA R~rPw
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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
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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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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
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-------
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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 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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/40.jpg)
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 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 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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/43.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/44.jpg)
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 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 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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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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/48.jpg)
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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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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/50.jpg)
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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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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/52.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/53.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/54.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/55.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/56.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/57.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/58.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/59.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/60.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/61.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/62.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/63.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/64.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/65.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/66.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/67.jpg)
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 …](https://reader033.fdocuments.in/reader033/viewer/2022051800/5ace4b687f8b9a93268e9daf/html5/thumbnails/68.jpg)
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
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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
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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
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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
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