1. Introduction
Concentrating solar power (CSP) is renewable energy technology and offers important advantages as it has the ability of thermal storage. In CSP systems, parabolic trough technology is the most mature and widely used solar thermal power technologies worldwide [
1,
2]. Parabolic trough receiver tubes are the core components, which convert solar energy into thermal energy. As shown in
Figure 1, the tubes are comprised of glass envelope coated in a layer of anti-reflective coating, and absorber tubes covered in a solar selective coating. The glass envelope and the metal tube are connected on both ends by a glass-metal seal and a metal bellows to achieve the necessary vacuum-tight annulus space and to accommodate for thermal expansion difference between the absorber tube and the glass envelope [
3,
4]. The annulus space must be in a vacuum state to significantly reduce the gas heat convection or conduction and to prevent the solar selective coating oxidizing in high temperatures, which can lead to heat losses from the parabolic trough receiver tubes. A getter is also emplaced within the annulus space to absorb hydrogen and other gases to maintain its vacuum state [
5,
6].
The failures of the receiver tubes have been a problem in parabolic trough solar power plants. The data on the Solar Energy Generating Systems (SEGS) plants that have been operating for a number of years show that receiver tubes have an accumulated failure rate of over 4% [
7]. Survey by the U.S. National Renewable Energy Laboratory (NREL) found that the most recent data for the Solar Energy Generating Systems (SEGS) plants indicated that receiver tube failures had decreased to 3.37% of the total field receivers per year [
8]. Failures involved vacuum loss, hydrogen infiltration, glass envelope breakage, and degradation of the coating. Of these failures, 55% were reported to involve broken glass and 29% involved loss of vacuum [
7,
8]. Changes in vacuum performance within the annulus space are inevitable, factors contributing towards the loss of vacuum include materials outgassing, gases permeation, vacuum leakage at seals and welds, getter failure, or saturation [
9,
10]. Liu et al. [
11] determined experimentally that there were H
2O, CO
2, H
2, N
2, Ar, and He in the annulus space. Moens [
10] presented that the long-term exposure of the heat transfer fluid (diphenyl oxide/biphenyl) to 400 °C temperatures could lead to hydrogen pressures that exceed the gas-absorbing capacity of the hydrogen getters, thereby causing the significant heat losses that were currently observed in several solar trough plants.
The vacuum performance of receiver tubes affects the efficiency and operating economy of the whole solar power system. The heat losses mainly result from the radiation between the solar selective coating and the glass envelope and the convection in the annulus space. In particular, once the annulus space in receiver tubes experiences a loss of vacuum, its heat losses would significantly increase, and its solar selective coating would also become less efficient due to oxidation in high temperatures, significantly reducing the thermal efficiency of the trough solar thermal power plants. In recent years, it has been discovered that hydrogen from degradation of heat transfer oils could permeate through the absorber tube into the vacuum annulus in many parabolic trough stations, which caused the increasing glass temperature and showed the so-called “hot tube phenomena” [
12]. Especially, if the partial pressure of hydrogen is more than 10 Pa in the annulus, the heat loss at the level is approximately a factor of 4 higher than the loss for a receiver with good vacuum [
3]. The annual plant revenue can then be reduced by as much as 20% by receivers infiltrated with hydrogen [
12,
13]. Meanwhile, vacuum life is the main factor that decides the life of parabolic trough receiver tubes. It is not only the key index that the manufacturers of receiver tubes focus on, but also the index that power plants operators and maintenance teams care most about. Therefore, it is necessary to identify the vacuum failure among all receiver tubes installed in a large solar field in order to maintain a higher level of thermal efficiency of the system. However, how to non-destructively test and evaluate the vacuum performance of the receiver installed in the solar filed is a technical problem at present.
Price et al. [
3] used an infrared camera to measure the surface temperature of the parabolic trough receiver in the solar field. This method makes it possible to roughly judge the heat loss according to the surface temperature of the receiver tube, but can not identify whether the heat loss is caused by vacuum failure or the solar selective coating degradation. It is also hard to judge the type of residual gas and its partial pressure. Pagola et al. [
14] developed a fluorescence sensor based on a single fiber measurement system that can monitor degradation of heat transfer fluid (HTF) and fluorescent substances generated by H
2 generation, and proposed a method to detect hydrogen molecules in heat transfer fluid as the hydrogen in residual gases comes from permeation of hydrogen in HTF. This method is helpful to define the quantity of hydrogen in the HTF and analyze how much hydrogen can permeate into the vacuum according to the hydrogen forming mechanism in the annulus. To analyze residual gases, Ren et al. [
15] presented a residual gas analysis (RGA) method for parabolic trough receiver tubes. The RGA system comprised of a receiver tube opening device, a high vacuum system and a quadrupole mass spectrometer (QMS), which is able to analyze the components and the partial pressure of the residual gases in the annulus space. The RGA method is destructive and needs to be tested indoor. Espinosa-Rueda et al. [
16] presented a procedure to evaluate the annulus gas of receivers in the solar field based on the plasma generation and spectral analysis in the annulus space. The method can be used in limits of working pressure range from 1 to 1000 Pa for some gases and mixtures. Setien et al. [
17] presented a surface temperature method to determine partial vacuum pressure of receiver tubes not completely damaged by a portable IR camera. It can distinguish partial vacuum pressure among 10
−2–10
5 Pa when the temperature of the receiver is higher than 300 °C and there should be air in the annulus. It does require accurate and careful measurement.
In this paper, a nondestructive testing method is developed to evaluate the vacuum performance of parabolic trough receiver tubes based on the principles of dielectric barrier discharge and spectrometric analysis. A novel test device, including two elements: a gas ionization system and a spectrometric analysis system, was developed to identify the gas composition and partial pressure and evaluate the state of vacuum in the annulus space. The feasibility and accuracy of the testing method were verified by using the RGA system [
15]. The different types of gases and partial pressures in the annulus space have been analyzed by using the novel device for the receivers in a series of experiments.
2. Methodology and Test Device
The non-destructive vacuum evaluation of the receiver tubes is based on the principles of dielectric barrier discharge and spectrometric analysis.
2.1. Principle of Dielectric Barrier Discharge
The dielectric barrier discharge (DBD) is a form of electrical discharge in low-pressure and atmospheric pressure. By placing an insulating dielectric barrier between two electrodes, plasma is generated between the electrodes. This is a typical form of high voltage alternating current discharge. Usually, DBD takes three forms according to the working pressure (P) and the discharge gap (D): (1) filamentous discharge; (2) dispersion of discharge; and (3) glow discharge [
18,
19]. For the given particular annulus space of the receiver tube, the plasma generation depends on the pressure and gas composition.
For filamentous discharge, the current in DBD is formed by the movement of charge in the micro-discharge channel. As the PD value is large, the breakdown process in DBD filamentous discharge belongs to the streamer breakdown. The generation process of discharge is the process from electron to initial electron avalanche and then to secondary electron avalanche, and finally produces discharge channel and forms self-sustaining discharge [
20].
Figure 2 shows the filamentous discharge in the annulus space of the receiver tube.
For diffuse discharge, it is an intermediate transition stage between filamentous discharge and glow discharge. It is known as a spot pattern discharge, which is a type of macro-structure displaying certain patterns in both time and space and is a typical non-linear spontaneous phenomenon.
Figure 3 shows the emission image of air diffuse discharge in the experiment.
For glow discharge, the breakdown process of DBD glow discharge belongs to Townsend breakdown as the PD value is small. Under the condition of low PD value, the positive ion is accelerated by the electric field and bombards the cathode, thus emitting secondary electrons. Then the electron avalanche is generated by the movement of the secondary electrons and the continuous collision of ionized atoms and molecules. Many electron avalanches generated by cathode emission overlap and influence each other in the discharge space, thus forming uniform discharge in the discharge space.
Figure 4 shows a luminescent image of DBD glow discharge of helium gas in the experiment.
2.2. Principles of Spectrometric Analysis
Light spectral emission is a spectrum formed by a large number of photons released by plasma gases from a high energy state to a low energy state. Under the action of electric energy, the outer electrons of atoms and molecules will get a certain amount of energy, causing them to be excited from the lower energy level
E1 to the higher energy level
E2. At this time, the atoms or molecules are in the excited state. Atoms gain energy Δ
E = E2 − E1 referred to as the excitation energy. An electron moving in a high energy state is in an unstable state. When it directly returns to its original energy state, it emits light at a characteristic wavelength of the atom composing the plasma [
21]:
where
c is the speed of light;
h represents Planck’s constant; and
E1 and
E2 represents the energy of an electron in a lower-level state and a higher-level state, respectively.
An electron in an excited state may also pass through several intermediate energy levels before it returns to its original energy level. At this time, light of several different wavelengths will be generated, forming several spectral lines in the spectrum, with wavelengths of respectively
where,
Ea, Eb,
Ec,
···En−1 are the energies of the intermediate stages.
Through the measurement and analysis of the profile spectrums, the type of gas compositions in the discharge channel formed during gas discharge can be obtained. Generally, the characteristic wavelengths of the light emitted by plasma are in the range from 200 to 1100 nm.
2.3. Test Method and Device
A non-destructive test method and device were developed for the non-destructive evaluation of the vacuum state and gas compositions in the annular space of the receiver tube in this study. The method included the dielectric barrier discharge to generate plasma and the spectrometric analysis to obtain the characteristic wavelength and the spectrum intensity of the light spectral emission. Meanwhile, when the dielectric barrier discharge cannot happen in the annulus space of the receiver tube, the voltage between the two electrodes depends on the pressure of the annulus space that can be measured. Thus, the pressure of the annulus space could be obtained through the relationship between the pressure and the voltage built by experiments. The flow chart of the test method is shown in
Figure 5.
The test device included two elements: a dielectric barrier discharge system and a spectral measurement system. The schematic of the test device is as shown in
Figure 6. The dielectric barrier discharge system included an HMV-1 high frequency power source (HFPS), which was made by Yuantuo technology Co. Ltd and a semicircular gas discharge applicator composed of an insulated fixture and a copper electrode and covered on the outer surface of the glass envelope. The HFPS with high voltage had one end connected to the copper electrode and the other end connected to the absorber tube (as the other electrode) of the parabolic trough receiver. The field of the dielectric barrier discharge was formed between the copper electrode covered on the glass envelope and the absorber tube so that the gas in the annular space could realize the dielectric barrier discharge and generate plasma. The absorber tube must be connected to the ground (GND) for safety. The HFPS had a constant current and working frequency mode so that it had the ability to measure the voltage between the two electrodes.
The spectral measurement system included a Maya-Pro spectrometer (trademark of Ocean optics), optical fiber and analysis software used to control the measurement and record the emission spectra of 200–1100 nm. One end of the optical fiber was connected to the spectrometer, and the other end was the fiber probe, which was inserted into the observation hole of the fixture. The fiber probe was fixed and kept the same place in the hole for each measurement. The fiber probe transmitted the light emitted in the annulus space to the spectrometer, and then the optical signal was converted into an electrical signal. Finally, the characteristic wavelength and the spectrum intensity could be analyzed through the Ocean View software (1.6.7, Ocean Optics, Florida, America).
For the solar field test, the device was easy to carry and convenient to operate. The semicircular gas discharge applicator must be fixed on the outer surface of the receiver. Then the copper electrode and the other electrode should connect to the HFPS. The absorber tube must be connected to the GND. In order to avoid the device from burning by the solar flux, the test should be taken when the parabolic trough collectors were temporarily defocused. Finally, the spectrometer could obtain and analyze the test data.
2.4. Experimental Design
In order to explore the relationship between the vacuum performance of receiver tubes and the spectral characteristics of dielectric barrier discharge, a series of experiments including pure argon, nitrogen, helium, and air under various pressures, which are the main gases in annulus space of the receiver, were carried out firstly.
Table 1 shows the types and the pressure range of the gases in the experiments. After filling various gases at different pressure into the annular space, the corresponding light spectral emissions of various gases at different pressure were recorded. Through these the light spectral emission, the corresponding characteristic spectral lines of each gas can be obtained. Then the non-destructive vacuum evaluation method was compared with the method by using the RGA system. Finally, the feasibility and accuracy of the non-destructive method were proved.
When the dielectric barrier charge reaches uniform discharge, the spectrometric measurement should be finished in 10 s to avoid the thermal effect of copper electrode.
The dimensions and materials of the parabolic trough receiver used in the experiment were shown in
Table 2.
4. Conclusions and Future Work
This paper proposed a non-destructive test method to evaluate the vacuum performance of the parabolic trough receiver by combining the DBD method and spectrometric analysis. The non-destructive test device including a gas ionization system and a spectrometric analysis system was developed. The discharge characteristics and spectrometric properties of four kinds of gases, which are the most likely gases to be found in the receivers, were studied in the experiments. The test results of the non-destructive vacuum evaluation method proposed were in good agreement with the RGA test results, which verified the feasibility and accuracy of this non-destructive test method. The relationship between the vacuum performance of receiver and the spectral characteristics of dielectric barrier discharge were obtained by a series of experiments. Through this study, the following conclusions could be obtained:
The working pressure range of each gas discharge was obtained by the experiments, which was 2–900 Pa for argon, 7–100000 Pa for helium, 3–80000 Pa for nitrogen, and 3–80000 Pa for air. The discharge characteristics of each gas were studied. The common features of each gas discharge were: when the gas pressure increase in the annulus space, the gas discharge mode was glow discharge and the discharge was circumferential distribution near the semicircular gas discharge applicator. Then the discharge mode turned to diffuse discharge, and the distribution of the discharge was only on the surfaces of the glass envelope and the absorber tube near the semicircular gas discharge applicator, and the patterns appeared. Finally, the gas discharge mode turned to filamentous discharge.
The emission spectra and characteristic peaks of each gas under different pressure were obtained to distinguish the gas composition in the receiver. According to the fitted function of the intensity ratio of two characteristic peaks and the pressure proposed in the paper, the intensity ratio of (I763/I810), (I667/I501), (I336/I390), and (I336/I390) were used to distinguish the partial pressure of argon, helium, nitrogen, and air, respectively.
Through experiment, the relationship between the vacuum performance of the receiver and the spectral characteristics of dielectric barrier discharge were obtained. This information is of great importance for the vacuum evaluation of the parabolic trough receivers. In the future, the hydrogen discharge characteristics and spectrometric properties will be tested when the safety of hydrogen discharge can be solved in the experiments. In addition, the on-site measurement of the vacuum performance of the receivers will be carried out in the solar field.