TEST RIG CONCEPT FOR EVALUATING THE PERFORMANCE OF A CO2 IMMERSED ELECTRO-MECHANICAL ROTOR SYSTEM UTILIZING GAS BEARINGS: PART-1 MECHANICAL AND ELECTRIC MACHINE DESIGN

Bugra Ertas; John Powers; Keith Gary; Dave Torrey; Joseph Zierer; Peggy Baehmann; Vandana Rallabandi; Tom Adcock; Nevin Anandika; Rahul A. Bidkar

doi:10.1115/GT2023-104093

TEST RIG CONCEPT FOR EVALUATING THE PERFORMANCE OF A CO₂ IMMERSED ELECTRO-MECHANICAL ROTOR SYSTEM UTILIZING GAS BEARINGS: PART-1 MECHANICAL AND ELECTRIC MACHINE DESIGN

Bugra Ertas
, John Powers
, Keith Gary
, Dave Torrey
, Joseph Zierer
, Peggy Baehmann
, Vandana Rallabandi
, Tom Adcock
, Nevin Anandika
, Rahul A. Bidkar

Electric Drives Research

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

4 Scopus citations

Abstract

This paper presents the mechanical and electric machine design of a 27krpm rotating test rig aimed at reducing technical risks with hermetic oil-free super-critical carbon dioxide (sCO₂) turbomachinery. The test rig rotor system is based on a conceptual turbomachine design discussed in a companion paper that evaluates a sCO₂ waste heat recovery (WHR) unit for land-based gas turbines at natural gas (NG) compressor stations. The key novelty of the hermetic sCO2 turbomachine concept is the utilization of additively manufactured CO₂ gas bearings and a CO₂-immersed direct-drive permanent magnet (PM) electric machine. The previous effort on conceptual design identified 3 main technical risks, which included thrust bearing load capacity, rotordynamics, and thermal performance of the system. Therefore, key requirements of the test vehicle include the ability to test the rotor system in a 400psi (27.6 bar) hermetic CO₂ operating environment, apply up to 1,500 lbs (6.7 kN) of rotor thrust loads, capability to assess rotordynamics with radial gas bearings, inclusion of instrumentation to assess thrust bearing load capability, and flexibility for varying secondary cooling flows to confirm thermal model predictions. Design topics such as rotordynamics, bearing design, and electric machine design are addressed in the paper, while highlighting critical elements. In addition, additive build trials for Inconel 718 radial and thrust bearings were performed to prove the manufacturability of the bearing design concepts. The results of the design efforts yield a test rig concept with ability to operate at 27,000 rpm, apply thrust loads to 1,500 lbs, deliver CO₂ up to 800psi, and modulate cooling flows.

Original language	English
Title of host publication	Supercritical CO2
Publisher	American Society of Mechanical Engineers (ASME)
ISBN (Electronic)	9780791887073
DOIs	https://doi.org/10.1115/GT2023-104093
State	Published - 2023
Event	ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023 - Boston, United States Duration: Jun 26 2023 → Jun 30 2023

Publication series

Name	Proceedings of the ASME Turbo Expo
Volume	12

Conference

Conference	ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023
Country/Territory	United States
City	Boston
Period	06/26/23 → 06/30/23

Funding

The authors gratefully acknowledge the U.S. Department of Energy, NETL, under Award Number DE-FE00031617, for their financial support for this work. The authors would also like to thank General Electric for allowing the publication of this work. This material is based upon work supported by the Department of Energy under Award Number DE-FE00031617. This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government of any agency thereof. The views and opinions of the authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

Access to Document

10.1115/GT2023-104093

Cite this

Ertas, B., Powers, J., Gary, K., Torrey, D., Zierer, J., Baehmann, P., Rallabandi, V., Adcock, T., Anandika, N., & Bidkar, R. A. (2023). TEST RIG CONCEPT FOR EVALUATING THE PERFORMANCE OF A CO₂ IMMERSED ELECTRO-MECHANICAL ROTOR SYSTEM UTILIZING GAS BEARINGS: PART-1 MECHANICAL AND ELECTRIC MACHINE DESIGN. In Supercritical CO2 Article v012t28a030 (Proceedings of the ASME Turbo Expo; Vol. 12). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/GT2023-104093

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title = "TEST RIG CONCEPT FOR EVALUATING THE PERFORMANCE OF A CO2 IMMERSED ELECTRO-MECHANICAL ROTOR SYSTEM UTILIZING GAS BEARINGS: PART-1 MECHANICAL AND ELECTRIC MACHINE DESIGN",

abstract = "This paper presents the mechanical and electric machine design of a 27krpm rotating test rig aimed at reducing technical risks with hermetic oil-free super-critical carbon dioxide (sCO2) turbomachinery. The test rig rotor system is based on a conceptual turbomachine design discussed in a companion paper that evaluates a sCO2 waste heat recovery (WHR) unit for land-based gas turbines at natural gas (NG) compressor stations. The key novelty of the hermetic sCO2 turbomachine concept is the utilization of additively manufactured CO2 gas bearings and a CO2-immersed direct-drive permanent magnet (PM) electric machine. The previous effort on conceptual design identified 3 main technical risks, which included thrust bearing load capacity, rotordynamics, and thermal performance of the system. Therefore, key requirements of the test vehicle include the ability to test the rotor system in a 400psi (27.6 bar) hermetic CO2 operating environment, apply up to 1,500 lbs (6.7 kN) of rotor thrust loads, capability to assess rotordynamics with radial gas bearings, inclusion of instrumentation to assess thrust bearing load capability, and flexibility for varying secondary cooling flows to confirm thermal model predictions. Design topics such as rotordynamics, bearing design, and electric machine design are addressed in the paper, while highlighting critical elements. In addition, additive build trials for Inconel 718 radial and thrust bearings were performed to prove the manufacturability of the bearing design concepts. The results of the design efforts yield a test rig concept with ability to operate at 27,000 rpm, apply thrust loads to 1,500 lbs, deliver CO2 up to 800psi, and modulate cooling flows.",

author = "Bugra Ertas and John Powers and Keith Gary and Dave Torrey and Joseph Zierer and Peggy Baehmann and Vandana Rallabandi and Tom Adcock and Nevin Anandika and Bidkar, \{Rahul A.\}",

note = "Publisher Copyright: Copyright {\textcopyright} 2023 by The United States Government.; ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023 ; Conference date: 26-06-2023 Through 30-06-2023",

year = "2023",

doi = "10.1115/GT2023-104093",

language = "English",

series = "Proceedings of the ASME Turbo Expo",

publisher = "American Society of Mechanical Engineers (ASME)",

booktitle = "Supercritical CO2",

}

Ertas, B, Powers, J, Gary, K, Torrey, D, Zierer, J, Baehmann, P, Rallabandi, V, Adcock, T, Anandika, N & Bidkar, RA 2023, TEST RIG CONCEPT FOR EVALUATING THE PERFORMANCE OF A CO₂ IMMERSED ELECTRO-MECHANICAL ROTOR SYSTEM UTILIZING GAS BEARINGS: PART-1 MECHANICAL AND ELECTRIC MACHINE DESIGN. in Supercritical CO2., v012t28a030, Proceedings of the ASME Turbo Expo, vol. 12, American Society of Mechanical Engineers (ASME), ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023, Boston, United States, 06/26/23. https://doi.org/10.1115/GT2023-104093

TEST RIG CONCEPT FOR EVALUATING THE PERFORMANCE OF A CO₂ IMMERSED ELECTRO-MECHANICAL ROTOR SYSTEM UTILIZING GAS BEARINGS: PART-1 MECHANICAL AND ELECTRIC MACHINE DESIGN. / Ertas, Bugra; Powers, John; Gary, Keith et al.
Supercritical CO2. American Society of Mechanical Engineers (ASME), 2023. v012t28a030 (Proceedings of the ASME Turbo Expo; Vol. 12).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Torrey, Dave

AU - Zierer, Joseph

AU - Baehmann, Peggy

AU - Rallabandi, Vandana

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AU - Anandika, Nevin

AU - Bidkar, Rahul A.

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N2 - This paper presents the mechanical and electric machine design of a 27krpm rotating test rig aimed at reducing technical risks with hermetic oil-free super-critical carbon dioxide (sCO2) turbomachinery. The test rig rotor system is based on a conceptual turbomachine design discussed in a companion paper that evaluates a sCO2 waste heat recovery (WHR) unit for land-based gas turbines at natural gas (NG) compressor stations. The key novelty of the hermetic sCO2 turbomachine concept is the utilization of additively manufactured CO2 gas bearings and a CO2-immersed direct-drive permanent magnet (PM) electric machine. The previous effort on conceptual design identified 3 main technical risks, which included thrust bearing load capacity, rotordynamics, and thermal performance of the system. Therefore, key requirements of the test vehicle include the ability to test the rotor system in a 400psi (27.6 bar) hermetic CO2 operating environment, apply up to 1,500 lbs (6.7 kN) of rotor thrust loads, capability to assess rotordynamics with radial gas bearings, inclusion of instrumentation to assess thrust bearing load capability, and flexibility for varying secondary cooling flows to confirm thermal model predictions. Design topics such as rotordynamics, bearing design, and electric machine design are addressed in the paper, while highlighting critical elements. In addition, additive build trials for Inconel 718 radial and thrust bearings were performed to prove the manufacturability of the bearing design concepts. The results of the design efforts yield a test rig concept with ability to operate at 27,000 rpm, apply thrust loads to 1,500 lbs, deliver CO2 up to 800psi, and modulate cooling flows.

AB - This paper presents the mechanical and electric machine design of a 27krpm rotating test rig aimed at reducing technical risks with hermetic oil-free super-critical carbon dioxide (sCO2) turbomachinery. The test rig rotor system is based on a conceptual turbomachine design discussed in a companion paper that evaluates a sCO2 waste heat recovery (WHR) unit for land-based gas turbines at natural gas (NG) compressor stations. The key novelty of the hermetic sCO2 turbomachine concept is the utilization of additively manufactured CO2 gas bearings and a CO2-immersed direct-drive permanent magnet (PM) electric machine. The previous effort on conceptual design identified 3 main technical risks, which included thrust bearing load capacity, rotordynamics, and thermal performance of the system. Therefore, key requirements of the test vehicle include the ability to test the rotor system in a 400psi (27.6 bar) hermetic CO2 operating environment, apply up to 1,500 lbs (6.7 kN) of rotor thrust loads, capability to assess rotordynamics with radial gas bearings, inclusion of instrumentation to assess thrust bearing load capability, and flexibility for varying secondary cooling flows to confirm thermal model predictions. Design topics such as rotordynamics, bearing design, and electric machine design are addressed in the paper, while highlighting critical elements. In addition, additive build trials for Inconel 718 radial and thrust bearings were performed to prove the manufacturability of the bearing design concepts. The results of the design efforts yield a test rig concept with ability to operate at 27,000 rpm, apply thrust loads to 1,500 lbs, deliver CO2 up to 800psi, and modulate cooling flows.

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M3 - Conference contribution

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Ertas B, Powers J, Gary K, Torrey D, Zierer J, Baehmann P et al. TEST RIG CONCEPT FOR EVALUATING THE PERFORMANCE OF A CO₂ IMMERSED ELECTRO-MECHANICAL ROTOR SYSTEM UTILIZING GAS BEARINGS: PART-1 MECHANICAL AND ELECTRIC MACHINE DESIGN. In Supercritical CO2. American Society of Mechanical Engineers (ASME). 2023. v012t28a030. (Proceedings of the ASME Turbo Expo). doi: 10.1115/GT2023-104093