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Presented by: Kristin Santamont
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WHAT IT TAKES TO HARNESS THE SUNIVANPAH SOLAR TOWER DESIGN
Kristin M. Santamont P.E.Senior Civil Engineer, Bechtel
Corporation© Bechtel 2012 | 1
IVANPAH SOLAR ELECTRIC GENERATING FACILITY
LocationSan Bernardino County, California, USA45 miles South West of Las Vegas
CustomerSolar Partners
Scope of ServiceEngineeringProcurementConstructionStartup
Project Completion2013
Units and Megawatts3 separate power plants totaling 392MW
© Bechtel 2012 | 2
“GREEN” POWER GENERATING FACILITY
363,000 tonnes of CO2 emissions avoided each year.
Equivalent to 70,000 cars
140,000 homes powered by the Ivanpah facility
Low impact construction techniques © Bechtel 2012 | 3
TYPICAL UNIT
SRSG
Air Cooled Condenser
Tower Mirror
FieldSteam Turbine Generator
© Bechtel 2012 | 4
PROJECT SITE
1
2
3
Project Size 3,600 Acres
Project Capacity Unit 1 = 126 MW
Units 2 & 3 = 133 MW
Solar Field Size Unit 1 = 895 acres
Unit 2 = 1078 acres
Unit 3 = 1209 acres
Number of Heliostats
Total = ~173,500
Unit 1 = 53,500
Units 2 & 3 = 60,000
© Bechtel 2012 | 5
173,500 HELIOSTATS
Enough reflective area to cover approximately 600 football fields
Enough mirrors to replace all the windows in the Empire State
Building…54 times
© Bechtel 2012 | 6
3,600 ACRE SITE
Manhattan Island
Manhattan Island
1
2
3
~ 6 square miles
Roughly 25% the size of Manhattan
© Bechtel 2012 | 7
Solar Tower Structure Design
© Bechtel 2012 | 8
SOLAR TOWER STRUCTURE 120’ tall Solar Receiver Steam Generator (SRSG)
54’ x 54’ footprint Each SRSG receives solar flux from mirror field Conventional steel braced frame
339’ tall Tower 70’ x 70’ footprint at base 45’ x 45’ main tower footprint Column splices located for modular erection
Concrete Foundation 120’ x 120’ in plan 9’ thick mat © Bechtel 2012 | 9
SOLAR TOWER 1,800 tons of structural steel
9 Tiers ~40’ tall Lowest 4 Tiers are “stick built” 5 Tiers Ground Assembled as Modules
Columns are 36” f pipe sections API 5L X56 material 1 ½” or 2” wall thickness
2” f A354 Grade BD bolts in splices
HSS16 square vertical braces
Traditional floor framing© Bechtel 2012 | 10
TOWER STEEL ERECTION
© Bechtel 2012 | 11
TOWER COLUMN SPLICES
Each column splice utilizes an identical circular pattern of 16 2”f A354 Grade BD bolts
Extra 4 bolts for shear loads at discrete locations only© Bechtel 2012 | 12
SRSG CONFIGURATION
Superheater Panel
Reheater Panel
Steam Generator
Panel
Protection Panel
Protection Panel
3 Stage Steam Generator
700 tons of structural steel for internal framing
Total weight including piping & equipment ~2,000 tons
Traditional framing geometry and member sizes
© Bechtel 2012 | 13
SRSG CONFIGURATION
Highly congested volume
External water walls with piping, headers and associated valves
Contains steam drum, silencers, access platforms, etc.
© Bechtel 2012 | 14
SOLAR RECOVERY STEAM GENERATOR (SRSG)
“Modularized” in 5 Tiers Ground Assembled and transported
to Tower Lifted in thirds due to weight limits
© Bechtel 2012 | 15
STRUCTURAL DESIGN
2007 California Building Code Seismic Design Category C Design Wind Speed 85 mph
Operating wind speed of 30 mph
Flexible Structure Governed by Wind
Flexible Structure Fundamental Period 3.3 seconds
© Bechtel 2012 | 16
VORTEX SHEDDING
© Bechtel 2012 | 17
WIND TUNNEL TESTING Boundary Layer Wind Tunnel Laboratory at
University of Western Ontario
Performed a Rigid Model Test
The measured cross-wind loads ~3 times calculated along-wind code prescribed load
© Bechtel 2012 | 18
TUNED MASS DAMPER Changing foundation and stiffening
structure deemed not practical
Opted for Tuned Mass Damper Solution
Required minimum 5% of critical damping to mitigate cross-wind response to an acceptable level
Other TMD requirements: 30 year design life Operating temperature range 10oF –
150oF
Idealized TMD with Suspended Mass &
Dashpots
© Bechtel 2012 | 19
TUNED MASS DAMPER Limited space in SRSG for
addition of TMD. 11’-4” X 11’-4” X 20’-6”
volume
TMD Location between
elevations 435’-5” – 456’-
1”
Volume identified for
TMD
© Bechtel 2012 | 20
TUNED MASS DAMPER FINAL DESIGN
Visco-damperVisco-damper arrangement
© Bechtel 2012 | 21
TUNED MASS DAMPER INSTALLATION
© Bechtel 2012 | 22
Heliostat Assembly
& Installation© Bechtel 2012 | 23
HELIOSTAT ASSEMBLY AREA
2 Pad Bonding Buildings
Heliostat Storage & Pit Lane
Material Laydown
Assembly Building
© Bechtel 2012 | 24
HELIOSTAT TRANSPORTATION
© Bechtel 2012 | 25
Record Number of Pylons Inserted in
One Day =
711
PYLON INSTALLATION
© Bechtel 2012 | 26
Record Number of Heliostats Installed in One Day =
512
HELIOSTAT INSTALLATION
© Bechtel 2012 | 27
CURRENT CONSTRUCTION STATUS
First Heliostats Calibrated in Unit 1 © Bechtel 2012 | 28
© Bechtel 2012 | 29
CURRENT CONSTRUCTION STATUS
Unit 1 Solar Field
Unit 2 Tower
Unit 3 SRSG Unit 1 Overall
ACKNOWLEDGEMENTS Boundary Layer Wind Tunnel Laboratory
GERB Vibration Control Systems
www.ivanpahsolar.com
© Bechtel 2012 | 30