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Figure 5: IST Physical Layout System power level is initially controlled by changing the speed of the turbo-compressor while operating the turbo- generator at a fixed speed. A compressor recirculation valve is utilized to maintain compressor surge margin by bypassing a portion of the compressor flow through the precooler rather than to the turbines. The turbo-compressor and turbo-generator designs [1- 4] incorporate a motor-generator within the pressure boundary (Figure 6). The compressor wheel is 1.54 in. (3.91 cm) diameter and the turbine wheels are 2.68 in. (6.81 cm) diameter. Two reciprocating compressors are used, the first lowers the pressure in the motor-generator cavities to reduce windage and bearing losses, the second provides supplemental cooling flow in addition to the CO2 flow that passes through the shaft seals. Of particular importance for the turbomachinery are 1) turbine and compressor operation relative to the design operating ranges to ensure stable operation and 2) shaft bearing loadings and temperatures to prevent bearing damage. The following test phases are planned. Sub-System Checkout and Loop Startup/Shutdown: This phase has been completed and included progression from initial sub-system shakedown operations leading to initial turbomachinery startup and shutdown transitions. Flowing Operations, Heatup to Hot Idle and Low Power Operations: This phase includes steady state loop and support systems operations from a cold idle condition followed by progressive increases in heat source temperature and turbomachinery shaft speed to produce up to 15% power. Steady State Power Operations: This phase includes operating at design heat source temperature and increasing turbomachinery shaft speeds transitioning to generation of electrical power up to the design loop rating of 100 kW. Transient Operations: This phase fully exercises system control features during power level changes that might be required in future applications due to either changes in heat source availability or output power requirements. Off Nominal Operations: This phase includes operations outside the normal operating limits to establish component and system tolerance and response. The most recent startup and operation experience is published separately [7]. This paper provides an overview of IST experience related to S-CO2 Brayton control system development, turbomachinery bearing temperature management, and turbomachinery shaft thrust monitoring. In addition, development of compact recuperator technologies for potential future use in the IST is summarized. S-CO2 BRAYTON CONTROL SYSTEM DEVELOPMENT BMPC has developed system models and control algorithms to evaluate plant control during IST operations including startup, steady-state and transient operation, and shutdown [5-6]. The model is used to generate pre-test predictions for IST operations, define initial control system parameters, and provide input to the test procedures before testing is performed. Test results are periodically incorporated into the model to update predicted system response and modify control system operating parameters. Control of compressor operating conditions is fundamental to demonstrating the desired system performance characteristics of the IST test program [5-6]. Compressor performance is determined by a combination of inlet conditions, rotational speed, and mass flow rate. The IST test Figure 6: IST Turbomachinery Internals The IST test plan [4] has been developed in a phased approach. During each phase component performance will be closely monitored to ensure operational limits are not exceeded. 3 Copyright © 2013 by ASMEPDF Image | SCO2 BRAYTON CYCLE DEVELOPMENT OVERVIEW
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