CCAMTG-2500 A04 — Assembly & Installation

Volume 15 defines the complete assembly and installation architecture for the CCAMTG-2500 A04, covering controlled factory build, common-rotor alignment, subsystem installation, site placement, foundation and grout interfaces, process and thermal hook-ups, electrical and controls integration, preservation, lifting, transport, storage and final mechanical-completion handover.

Main Public Assembly Baseline

• Machine Class: 2.5 MW-Class Dual-Mode Compressed-Air Energy Storage / Recovery Magnetic Motor-Generator Machine
• Net AC Generation: 2.50 MW
• Nominal Rotor Speed: 12,000 rpm
• Master Air Mass Flow: 12.2 kg/s
• Compression Range: 1.20 bara → ~31 bara
• Expansion Range: ~31 bara → 1.20 bara
• DC Bus: 1,500 VDC
• BESS Energy Capacity: ~5 MWh LFP
• Dry Skid Mass (Estimated): ~22,000 kg

A04 Assembly Status: Public baseline values identify the current A04 machine configuration. Final assembly dimensions, alignment tolerances, foundation details, anchor requirements and supplier-dependent clearances remain controlled by their approved engineering calculations, released drawings and site-specific design.

Assembly & Installation Overview

• Factory machine assembly
• Common rotor alignment
• Compressor assembly and mounting
• PMSM/PMG installation
• Turbine assembly and mounting
• Active magnetic bearing installation
• Touchdown-bearing installation
• Thermal and cooling equipment installation
• HP buffer vessel installation
• Electrical and control integration
• Site installation and grouting
• Preservation, shipping and storage

Assembly Configuration Control

• Assembly follows the approved A04 configuration baseline
• Released subsystem drawings govern installed geometry
• Approved engineering changes are incorporated before irreversible assembly
• Manufactured and purchased components require QA release before installation
• Acceptance metrology uses calibrated and traceable equipment
• Pressure boundaries remain protected from contamination before closure
• Critical bolted joints use joint-specific controlled preload procedures
• Rotor handling uses certified tooling and protected surfaces

Primary Assembly Datums

• Common rotor centreline forms the principal rotating-machine datum
• Skid longitudinal reference controls machine positioning
• Skid transverse reference controls cross-machine positioning
• Compressor, PMSM/PMG and turbine sections align to the common rotor axis
• Bearing and casing centres reference the same controlled alignment system
• Final dimensional acceptance follows released drawings and analysis-frozen values

Factory Assembly Preparation

• Verify component identity and quantities
• Inspect incoming preservation and shipping condition
• Establish controlled clean assembly area
• Implement foreign-material-exclusion controls
• Verify calibrated assembly and metrology tooling
• Verify certified lifting fixtures
• Prepare protected rotor stands and handling equipment
• Establish assembly datums before machinery placement

Structural Skid Preparation

• Inspect primary skid datum surfaces
• Inspect machinery mounting pads
• Establish longitudinal and transverse reference datums
• Establish the common rotor reference axis
• Install controlled soleplates and chocks
• Preserve adjustment capability until rotor alignment is accepted
• Record support coordinates and elevations

Compressor Assembly

• Install compressor casing components in the released sequence
• Install three-stage diffuser architecture
• Install compressor impeller and rotor assemblies
• Install compressor labyrinth sealing systems
• Protect aerodynamic surfaces throughout assembly
• Verify component identity and orientation
• Inspect rotor and casing interfaces before closure

PMSM/PMG Assembly

• Install the motor-generator stator and housing
• Install the high-speed rotor module
• Protect permanent-magnet rotor-retention systems
• Protect electrical insulation systems
• Connect machine cooling interfaces
• Perform required insulation and continuity checks
• Record supplier and machine serial information

Turbine Assembly

• Install turbine rotor and wheel assemblies in controlled stage order
• Install nozzle guide vane assemblies
• Install turbine labyrinth sealing systems
• Install turbine casing and exhaust interfaces
• Protect released aerodynamic geometry from unapproved rework
• Verify wheel and guide-vane identity and orientation
• Inspect rotating and casing interfaces before closure

Active Magnetic Bearing Installation

• Install radial AMB stations concentric with the common rotor geometry
• Install the double-acting axial magnetic bearing
• Install radial rotor-position probes
• Install redundant axial position sensing
• Install rotor phase and speed sensing
• Verify sensor orientation and polarity
• Verify controller channel mapping
• Record final supplier-controlled bearing and sensing settings

Touchdown Bearing Installation

• Install independent touchdown support at each radial magnetic-bearing station
• Maintain separation between touchdown and normal non-contact support functions
• Verify mechanical support orientation
• Protect bearing surfaces during assembly
• Confirm monitoring functions before high-speed operation
• Final supplier-certified clearances and fault capabilities govern release

High-Speed Coupling Installation

• Install diaphragm couplings between rotor modules
• Establish preliminary axial positioning
• Verify coupling pilots and mating interfaces
• Inspect coupling-face condition and runout
• Do not perform final coupling closure before alignment acceptance
• Apply final joint preload only after approved rotor alignment

Rotor Alignment Procedure

• Alignment performed as a controlled metrology process
• Common rotor datum established from approved machine geometry
• Bearing, motor-generator and casing centres measured to the same reference
• Rotor journal and coupling interfaces inspected before alignment
• Horizontal and vertical coupling alignment measured using approved metrology
• Machinery adjusted using engineered chocks, soleplates and shims
• Process piping is never used to pull machinery into alignment
• Final alignment is rechecked after critical joint preload

Thermal Growth & Hot Alignment

• Cold assembly alignment can include approved intentional offsets
• Thermal expansion is incorporated into the alignment model
• Magnetic-bearing operating position is included in final alignment engineering
• Process and cooling piping effects are checked after connection
• Electrical and thermal hook-ups are checked for installation-induced movement
• Operating shaft position and thermal growth are verified during commissioning

Critical Joint Assembly

• Machinery mounting joints use controlled installation methods
• Casing joints use released gasket and seal procedures
• Coupling joints use calculated joint preload
• Critical fasteners are installed and inspected individually
• Locking systems are verified after tightening
• Assembly records preserve joint identity and final installation status

Air Intake & Compressor Process Installation

• Install air intake and filtration equipment
• Install inlet guide vane hardware
• Install compressor discharge collection system
• Install protective anti-surge recycle equipment
• Verify process flow direction
• Verify valve fail-safe orientation
• Verify actuator and instrumentation orientation

Thermal & Cooling Installation

• Install compressor intercoolers
• Install aftercooler and heat-recovery equipment
• Install turbine preheater
• Install turbine interstage reheaters
• Install the closed machine-cooling package
• Connect controlled drains and vents
• Install thermal instrumentation
• Preserve thermal expansion and equipment serviceability

HP Buffer Vessel Installation

• Install the HP buffer vessel on its approved support interface
• Verify vessel support alignment
• Control process nozzle loads
• Install independent pressure-relief protection
• Install controlled drain and depressurization interfaces
• Install pressure and temperature instrumentation
• Preserve access to inspection and maintenance locations

Pressure-Boundary Hook-Up

• Maintain correct process-flow direction
• Maintain correct pressure and temperature service classification
• Install fail-safe high-pressure isolation
• Maintain protective compressor recycle functionality
• Preserve independent mechanical overpressure protection
• Do not allow temporary shipping or commissioning items to defeat relief paths
• Support piping independently of rotating machinery
• Recheck rotor alignment after final pressure-system hook-up

Electrical Installation

• Install electrical conversion enclosures
• Install active rectifier and inverter equipment
• Install common DC power-system equipment
• Install magnetic-bearing amplifiers and controllers
• Install PLC, SIS, HMI and SCADA equipment
• Implement approved electrical isolation and precharge architecture
• Verify polarity and insulation
• Install touch-safe barriers and required protective interfaces

Cabling & Instrumentation Installation

• Route power cables through approved pathways
• Segregate power, control, instrumentation and network cabling
• Maintain required cable support and bend radius
• Install shielding and earthing correctly
• Install uniquely tagged pressure, temperature and flow instruments
• Install rotor-position, vibration and speed sensors
• Verify cable continuity and polarity
• Verify instrumentation calibration records

Earthing & Bonding Installation

• Bond the machine structure
• Bond the structural skid
• Bond electrical enclosures
• Bond cable trays
• Bond guards and exposed conductive components
• Verify continuity before electrical energization
• Record final earthing and bonding inspection results

Machine Guards & Access Systems

• Install rotating-equipment guards
• Install hot-surface insulation and protection
• Install equipment labels and safety markings
• Install access panels
• Preserve valve and instrumentation access
• Preserve maintenance-removal envelopes
• Ensure guards do not interfere with approved lifting interfaces

Pre-Rotation Mechanical Checks

• Perform approved static rotation and clearance checks
• Verify there is no unintended rotor contact
• Verify magnetic-bearing levitation functionality
• Verify rotor centring
• Verify touchdown-bearing monitoring
• Zero and verify rotor-position sensing
• Establish baseline vibration and probe readings

Site Readiness

• Verify installation permits and method statements
• Verify lifting and access routes
• Verify utilities and laydown areas
• Verify environmental installation conditions
• Survey foundation position and elevation
• Inspect foundation condition before machinery placement
• Verify site-specific anchor and structural design

Foundation & Grout Interface

• Prepare machinery foundation surfaces
• Install approved leveling systems
• Set the skid to controlled survey datums
• Establish the rotor centreline reference before grouting
• Install anchors only to the approved site structural design
• Use approved high-strength non-shrink machinery grout
• Verify grout placement and curing before final load transfer
• Recheck rotor alignment after foundation load transfer

Machine Positioning & Lifting

• Use only certified machine lifting points
• Use current as-built shipping mass and centre-of-gravity data
• Use approved lift calculations and rigging geometry
• Do not lift from process nozzles or rotating-equipment casings
• Do not lift from magnetic-bearing housings, piping, guards or cable trays
• Protect the common rotor train from handling shock
• Maintain controlled lifting exclusion zones

External System Hook-Ups

• External compressed-air storage interface
• Air intake and exhaust interface
• Thermal-energy storage interface
• Machine cooling interface
• Drain and vent systems
• Grid, transformer and PCS interfaces
• Battery energy storage interface
• Controls and communications interfaces

Cooling & Thermal Circuit Completion

• Flush and clean thermal circuits
• Flush and clean cooling circuits
• Use approved working fluids
• Vent circuits before operation
• Perform leak checks
• Verify filter installation direction
• Verify chemistry and cleanliness requirements before operation

Preservation & Shipping

• Close quality-release requirements before preservation
• Clean and dry internal cavities
• Protect precision-machined surfaces
• Protect electrical and electronic enclosures
• Protect process openings with controlled covers
• Install approved rotor shipping restraints
• Apply transport-appropriate weather protection
• Use transport-condition indicators where required

Transport Controls

• Transport restraints use approved structural attachment points
• Machine is secured against longitudinal, lateral and vertical transport loads
• No tie-down through process nozzles or unapproved casings
• Rotor and precision interfaces are protected from shock
• Transport events outside approved limits trigger engineering inspection
• Alignment and runout checks may be repeated after abnormal transport events

Storage Controls

• Store the machine in a level and secure location
• Maintain a dry controlled environment
• Inspect preservation status periodically
• Monitor humidity and desiccant condition
• Renew preservation systems at approved intervals
• Follow supplier requirements for motor-generator and magnetic-bearing systems
• Manage battery systems separately under the approved BESS supplier requirements

Foreign Material Exclusion

• Maintain controlled logs for temporary items entering machine cavities
• Account for temporary plugs and caps
• Account for loose tools and fasteners
• Account for cleaning materials and desiccant bags
• Maintain process-air paths clean and dry
• Prevent machining debris and weld contamination
• Control stainless-steel contamination
• Ensure temporary blinds do not defeat safety or relief functions

Assembly Hold Points

• Incoming components accepted before assembly
• Skid datums accepted before machinery placement
• Rotor modules accepted before casing closure
• AMB, TDB and probes accepted before coupling closure
• Rotor alignment accepted before final mount and coupling preload
• Critical joint preload complete before concealment
• Pressure boundaries verified before insulation or guarding
• Electrical installation verified before energization
• Factory mechanical completion verified before FAT
• Foundation and anchors accepted before site machine placement
• Grout accepted before final structural load transfer
• Final site alignment accepted after all major hook-ups

Assembly & Installation Records

• Component serial and material traceability
• Skid and foundation surveys
• Chock and shim records
• Grout and anchor records
• Rotor alignment records
• Critical joint preload records
• Pressure-boundary and leak-test records
• Cable and earthing records
• Instrumentation calibration records
• Foreign-material-exclusion closure records
• Lifting, transport and preservation records
• NCR, repair and engineering-change records
• Final redlined and as-built configuration records

Mechanical Completion

• Final assembly inspection completed
• All required guards installed
• Safety-critical punch items closed
• Temporary items accounted for
• Pressure-relief paths confirmed available
• Rotor rub and alignment issues resolved
• Magnetic-bearing sensing verified
• Earthing and bonding verified
• Machine handed over under controlled commissioning procedures

Commissioning Interface

• V15 ends at controlled mechanical and electrical completion
• First energized operation occurs under the commissioning procedures
• First pressurization occurs under controlled commissioning procedures
• First high-speed rotation occurs under controlled commissioning procedures
• Startup permissives verify emergency-stop health
• Cooling and magnetic-bearing systems must be available
• Electrical precharge and source availability must be proven
• Valve states and safety-trip systems must be verified before operation

Safety-Critical Installation Functions

• Independent mechanical overpressure protection
• Fail-safe high-pressure isolation
• Protective compressor anti-surge recycle
• Redundant speed protection
• Active magnetic bearing fault management
• Fire-protection integration
• Electrical insulation and earthing protection
• Machine guarding
• Controlled depressurization
• Safe rotor coast-down provisions

V15 Controlled Procedure Set

• Factory Assembly Procedure
• Rotor Alignment Procedure
• Site Installation Procedure
• Preservation / Shipping Procedure
• Assembly travelers and hold-point releases
• Alignment survey and as-found / as-left records
• Foundation, anchor and grout installation records
• Preservation and transport-release records
• Mechanical-completion and turnover dossier

Assembly & Installation Release Philosophy

• All mechanically coupled rotor sections remain on the common rotor centreline
• Every pressure boundary retains its approved material, service and relief architecture
• Every critical bolted joint uses calculated preload and controlled installation
• Every acceptance measurement records the governing datum and calibrated instrument
• No safety-critical NCR may remain open at release
• No temporary item may remain unaccounted for
• No pressure-relief path may be defeated
• No unresolved rotor rub, alignment or magnetic-bearing issue is permitted at handover
• Final installed values come only from approved drawings, analyses, supplier data and site-specific engineering