CCAMTG-2500 A04 — System Architecture & Functional Integration

Volume 13 defines the system-level architecture and functional integration of the CCAMTG-2500 A04, coordinating how the compressor, turbine, common rotor, PMSM/PMG, active magnetic bearings, touchdown bearings, thermal-energy system, HP buffer vessel, external compressed-air storage, battery energy storage, electrical conversion, structural skid, instrumentation, controls, protection and external site systems operate as one integrated machine.

Main Public System Specifications

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 Design Baseline: Published specifications represent the current CCAMTG-2500 A04 design baseline. Final analysis-dependent, supplier-dependent, code-dependent and site-dependent values remain controlled by the applicable approved engineering calculations and drawings.

System Architecture Overview

Mechanical system integration
Pneumatic process integration
Thermal-energy integration
Common rotor integration
Active magnetic bearing integration
Electrical power-conversion integration
Battery energy-storage integration
Structural and foundation integration
Instrumentation and controls integration
Safety and machine-protection integration
External site-interface control

Charge Electrical Path

Grid and/or BESS energy supplied through the electrical conversion architecture
Electrical power routed through switchgear and power-conversion equipment
Common DC system supplies the motor inverter
PMSM/PMG operates in motor mode during charge operation
Electrical control coordinated with rotor speed and compressor loading

Charge Mechanical Path

PMSM/PMG develops shaft torque
Torque transfers through the common rotor architecture
Three-stage compressor receives the motoring power
Coupling interfaces accommodate approved rotor and thermal behaviour
Mechanical operation remains coordinated with magnetic-bearing support

Charge Pneumatic Path

Ambient air enters through the intake and filtration system
Conditioned air enters the three-stage compressor
Compressed air passes through staged intercooling
Final compressed air passes through aftercooling and heat recovery
HP buffer vessel stabilizes the downstream compressed-air path
Compressed air is transferred to the external CAES storage interface

Charge Thermal Path

Compression heat is recovered from the intercooling and aftercooling systems
Recovered heat transfers into the closed thermal-energy loop
Thermal energy is directed to TES storage or approved heat rejection
Thermal control coordinates with compressor operation and storage state
Recovered thermal energy remains available for generation-mode reuse

Generation Pneumatic Path

Stored compressed air returns from the external CAES system
Fail-safe isolation controls the storage interface
Compressed air passes through the HP buffer vessel
Turbine admission control regulates the generation flow path
Air is preheated before the first turbine stage
Three-stage expansion includes interstage reheating
Final turbine exhaust is routed to the defined discharge or return interface

Generation Mechanical Path

Turbine expansion produces shaft torque
Turbine wheels transfer mechanical energy into the common rotor
High-speed couplings transfer torque between machine modules
Common rotor drives the PMSM/PMG in generator operation
Rotor support and thrust control remain coordinated with the AMB system

Generation Electrical Path

PMSM/PMG operates in generator mode
Generated variable-frequency electrical power passes through active rectification
Electrical energy transfers into the common DC system
Bidirectional PCS manages energy flow
Generated power can be directed to the BESS and/or grid interface
Electrical protection remains active throughout generation

Machine Cooling Integration

Closed cooling package serves the PMSM/PMG
Converter and PCS thermal loads integrated where applicable
AMB amplifier thermal loads integrated with machine cooling
Machine auxiliaries included within the cooling architecture
Heat rejection coordinated with site ambient conditions
Cooling availability forms part of operating permissives and trip logic

Common Rotor Integration

Compressor, PMSM/PMG and turbine share one instantaneous shaft speed
Rotor sections integrated through high-speed diaphragm couplings
Common rotor centreline provides the principal rotating-machine datum
Rotor architecture supports modular balancing and serviceability
Rotor interfaces coordinated with rotordynamics, torsional and structural analysis
Thermal growth accommodated within the approved coupling and support architecture

Compressor & Anti-Surge Integration

Three-stage centrifugal compression architecture
Staged pressure rise and staged cooling
Compressor operating state coordinated with shaft speed
Protective anti-surge recycle architecture
Anti-surge logic uses pressure, corrected flow, speed and temperature information
Recycle cooling limits excessive inlet-temperature escalation
Protective recycle system designed to move toward a safe state during applicable faults

Turbine & Reheat Integration

Three-stage reheated turbine expansion architecture
Preheater conditions the Stage 1 inlet
First interstage reheater restores thermal conditions before Stage 2
Second interstage reheater restores thermal conditions before Stage 3
Turbine admission control fails toward the defined safe state
Turbine operation coordinated with TES availability and machine protection
Aerodynamic geometry remains controlled by the turbine engineering package

HP Buffer & External CAES Integration

HP buffer vessel provides local pressure and flow stabilization
Buffer interfaces with compressor discharge and external CAES storage
Buffer interfaces with the turbine admission path
External storage isolation uses fail-safe architecture
Passive reverse-flow protection incorporated where required
Independent mechanical overpressure protection retained
Controlled blowdown and depressurization integrated with the safety system

Thermal & TES Integration

Compression heat recovered during charge mode
TES interface stores recoverable thermal energy
Stored thermal energy supports turbine preheating and reheating during generation
Thermal interfaces coordinated with heat-exchanger performance
Machine cooling remains distinct from the BESS supplier thermal system
Thermal sizing and pressure-loss values remain controlled by the thermal engineering package

Active Magnetic Bearing Integration

Multiple radial magnetic bearing stations support the rotor train
Axial magnetic bearing provides thrust control
Rotor-position sensing supports closed-loop bearing control
Redundant rotor-speed and phase sensing supports control and protection
AMB system status forms part of machine startup permissives
Fault conditions coordinate pressure isolation and rotor coast-down

Touchdown Bearing Integration

Independent touchdown support at the radial bearing stations
Backup mechanical support during defined levitation-loss events
Fault coast-down coordinated with rotor dynamics and AMB control
Touchdown bearing health monitored before machine startup
Touchdown system remains separate from normal non-contact running support

PMSM/PMG Integration

High-speed permanent-magnet motor-generator architecture
Motor operation during charge mode
Generator operation during generation mode
Bidirectional mechanical-electrical energy conversion
Closed machine-cooling interface
Rotor retention and electromagnetic design coordinated with the common rotor system

Electrical Energy Architecture

Bidirectional motor-generator power conversion
Common DC electrical backbone
Main isolation and precharge functions
Continuous insulation monitoring
Bidirectional PCS interface
BESS energy-buffer interface
Grid transformer and switchgear interface
Electrical metering and protection architecture

BESS & Energy Management Integration

BESS provides electrical energy buffering and support
State-of-charge information integrated with machine dispatch logic
PCS manages bidirectional battery energy flow
BMS safety information integrated with the control system
Energy-management strategy coordinates charging, generation and reserve operation
Final BESS safety and dispatch settings remain supplier and analysis controlled

Valve & Safe-State Architecture

External storage isolation configured toward a closed safe state
Turbine inlet control configured toward a closed safe state
Compressor discharge isolation configured toward a closed safe state
Compressor anti-surge recycle configured toward an open protective state
Reheater isolation coordinated with the hazard study
Independent buffer overpressure relief remains mechanically available
Controlled blowdown integrated with machine depressurization strategy
Passive non-return devices prevent reverse flow where required

Instrumentation Integration

Compressor pressure measurement
Buffer-vessel redundant pressure monitoring
Redundant main air-flow monitoring
Compressor inlet and discharge temperature monitoring
Turbine inlet and reheat temperature monitoring
Turbine outlet temperature monitoring
Rotor vibration and position monitoring
Redundant rotor-speed measurement
Filter-condition monitoring
Condensate and drain monitoring where required

Operating State Machine

Off / Isolated
Standby
Levitate / Prestart
DC Precharge
Charge Start
Charge Run
Generation Start
Generation Run
Controlled Stop
Trip / Emergency

Startup Permissives

Emergency-stop system healthy
High-pressure system within approved startup state
Cooling available and proven
AMB controller healthy
Rotor levitated and centred
Touchdown-bearing monitoring healthy
DC bus precharge complete
Required electrical source available
Isolation valves proven in commanded state
No active critical protection trips

Charge-Mode Functional Sequence

Establish magnetic-bearing levitation and machine cooling
Precharge the electrical DC system
Enable motor operation and accelerate the rotor
Establish the compressor flow path
Operate protective recycle during initial compressor loading
Transition toward stable compressor flow
Enable staged cooling and thermal-energy recovery
Control storage pressure within the approved operating envelope
Unload and transition to standby or stop at the commanded storage state

Generation-Mode Functional Sequence

Verify external storage and thermal-energy availability
Establish magnetic-bearing levitation and cooling
Establish the electrical DC system
Isolate the compressor high-pressure path
Introduce turbine inlet flow under controlled ramping
Enable turbine preheat and interstage reheating
Transition the PMSM/PMG from motoring support to generation
Regulate rotor speed and electrical export
Maintain approved flow, thermal and pressure conditions

Trip & Safe-Shutdown Integration

Overspeed initiates turbine energy isolation and torque removal
AMB instability initiates high-pressure isolation and coast-down strategy
High vibration initiates controlled machine shutdown
High buffer pressure isolates compressor discharge while independent relief remains available
Cooling failure initiates unloading and controlled shutdown
Electrical faults isolate affected power-conversion paths
Fire and emergency-stop conditions initiate coordinated energy isolation

Subsystem Interface Control

General arrangement and datum interfaces
Air-intake and compressor interfaces
Compressor and thermal-system interfaces
Buffer-vessel and turbine interfaces
Rotor and magnetic-bearing interfaces
Thermal and electrical interfaces
Manufacturing and QA interfaces
Assembly and installation interfaces
Maintenance and lifecycle interfaces
Controls and safety interfaces
Analysis and design-freeze dependencies

External Site Interfaces

External compressed-air energy storage
Bidirectional electrical grid connection
Site foundation and structural interface
Ambient heat-rejection interface
Thermal-energy storage interface
Drain and blowdown disposal interface
Site utilities and control communications

Functional Completeness Rules

Every manufactured part has controlled identification and inspection requirements
Every purchased item has a defined procurement and supplier-data interface
Every process connection has a controlled service and interface definition
Every instrument is reconciled across process, controls and commissioning documentation
Every electrical load is reconciled with load, cable and protection documentation
Every safety function traces to hazard analysis, sensors, logic and final elements
Preliminary values are not silently promoted to fabrication-release status
Interface changes require controlled impact assessment