A Perspective on the Process and Turbomachinery Design of Compressed Air Energy Storage Systems

Abstract

The present paper will describe the Baker Hughes experience in the development of the turbomachinery equipment for Hydrostor's advanced compressed air energy storage (A-CAES) system. At the core of a compressed air energy storage (CAES) plant, there is an air compressing system, followed by an air expander used to recover the stored energy. To achieve a reliable and effective solution, the expander is obtained from the architecture of Baker Hughes steam turbines, which was adapted to match the specific process needs. The criticalities that were addressed and solved to derive the expanders from the original steam turbine are presented. Specifically, the paper describes the activities performed to optimize the inlet and exhaust sections of each segment, the development of the blades for high atmospheric volume flow, and the implications that thermal transients have on the machine reliability. The inlet and exhaust sections were arranged according to the layout constraints, which were set to mitigate the effects of the thermal stresses and to reduce the weight to facilitate the machine transportation, while maintaining high aero-performance. As for the expander, a single-body configuration was selected to optimize capital expenditures and reduce leakage to atmosphere. A new set of blades derived from Baker Hughes's Steam Turbine stages were developed. This new stage is characterized by rotating blades with high radius ratio (HRR); therefore, an optimization strategy was adopted to include the mechanical constraints from the beginning of the design cycle and obtain a final geometry that can be used with different flow path and operating conditions. Finally, the three-dimensional full Navier Stokes Computational fluid dynamics analysis was used to assess the performance of the new stages in nominal and off-design conditions. A detailed analysis of the thermal transient of the expander parts with finite element analysis methods was performed to assess the life expectations of the equipment. The finite element analysis results are discussed in the paper to show the capability of the machine to sustain an extremely fast start up sequence. Compressor train is characterized by a multiple body configuration. A detailed optimization was performed to improve the efficiency and the availability of the selected solution. The low-pressure axial compressor discharge section has been optimized to reduce losses and a detailed study of rotor has been performed to evaluate the capability to withstand a high number of start and stop cycles.