1. 1 | Program Name or Ancillary Texteere.energy.gov Water Power Peer Review Design of Submersible Generator for MHK Rob Cinq-Mars, President Free Flow Energy, Inc. (800) 928-0435; Rob@FreeFlowEnergy.com 6 September 2011 Project Number: DE-EE0004567

2. 2 | Wind and Water Power Programeere.energy.gov Purpose, Objectives The design of a submersible generator – key features: –designed by motor/generator industry professionals –work with multiple turbine styles –critical subassembly of current energy conversion systems Objectives: accelerate MHK improving performance lowering cost, and improve operation and maintenance

3. 3 | Wind and Water Power Programeere.energy.gov Project Team

4. 4 | Wind and Water Power Programeere.energy.gov Industrial Partners

5. 5 | Wind and Water Power Programeere.energy.gov Technical Approach - Tasks 1.Assess resources tidal and river for: –proper sizing –form factor –power rating –ambient operating conditions. 2.Determine appropriate topology 3.Electromagnetic circuit design 4.Mechanical design 5.Investigate Manufacturing Requirements 6.Cost Analysis 7.Commercialization and future research

6. 6 | Wind and Water Power Programeere.energy.gov Technical Approach – Key Issues MHK Generators - where wind generators were in ‘70s Eliminate gearbox (Rim Mount Design) Get topology, sizing, power and form factor right Components designed/manufactured by industry Work with multiple turbines Design for harsh marine environment Coupling method

7. 7 | Wind and Water Power Programeere.energy.gov Schedule & Budget Schedule Initiation date:11/1/2010 Planned completion date: 10/31/2011 Design Completed, report published, paperwork complete Budget: On schedule, on budget, additional cost share provided Budget History FY2009FY2010 - FY2011 DOECost-shareDOECost-share N/A $160K$54K

8. 8 | Wind and Water Power Programeere.energy.gov Project - Preliminary Differences between renewable and conventional generation Appreciate difference between power, energy and nameplate capacity Differences between tidal and inland stream flows Design for common siting conditions not extreme / rare Lessons learned from wind Many different turbine styles, sizes, & stages of development Review and understanding of MHK state of art Understanding of regulatory, permitting, siting Acceptance of 35% efficiency Baseline estimate of “realistic” siting conditions

9. 9 | Wind and Water Power Programeere.energy.gov Resource Assessment - Tidal What’s Realistic?

10. 10 | Wind and Water Power Programeere.energy.gov Resource Assessment - Area Area & # Turbines to Generate 1 MW Assumes 35% eff (Gorlov)

11. 11 | Wind and Water Power Programeere.energy.gov Resource Assessment – Distribution & Area

12. 12 | Wind and Water Power Programeere.energy.gov Resource Assessment - Tidal UK Current Predictions

13. 13 | Wind and Water Power Programeere.energy.gov Resource Assessment - Tidal Tacoma Narrow Currents

14. 14 | Wind and Water Power Programeere.energy.gov Resource Assessment - Tidal Maine, Washington, and AK Velocity Frequency Histograms

15. 15 | Wind and Water Power Programeere.energy.gov Resource Assessment - Tidal Most recently – Georgia Tech / DOE Model, Mid Atlantic Currents

16. 16 | Wind and Water Power Programeere.energy.gov Resource Assessment - Tidal Mid – Atlantic Depths

17. 17 | Wind and Water Power Programeere.energy.gov Resource Assessment - Inland

18. 18 | Wind and Water Power Programeere.energy.gov Resource Assessment – Inland chan_dischargeChannel FlowThe channel discharge in cubic feet per second chan_widthChannel WidthThe channel width in feet chan_velocityChannel VelocityThe mean velocity in feet per second chan_areaChannel AreaThe channel area in square feet chan_depth (calculated)Channel DepthAverage depth in meters USGS Field Descriptions

19. 19 | Wind and Water Power Programeere.energy.gov Resource Assessment - Inland Channel Velocity (mps)

20. 20 | Wind and Water Power Programeere.energy.gov Channel Area - Inland USGS Inland Data – Channel Area (m^2)

21. 21 | Wind and Water Power Programeere.energy.gov Channel Depth - Inland

22. 22 | Wind and Water Power Programeere.energy.gov Channel DischargeCMS

23. 23 | Wind and Water Power Programeere.energy.gov Resource Assessment Cont. Depth: 10 – 30 m (Top: Nav Clearance, Bottom: Permitted Sites) Salinity: 35 ppt Temp: 35-90 F, 2-32 C

24. 24 | Wind and Water Power Programeere.energy.gov Analysis of turbines Proprietary data was shared with FFE based upon completed NDAs. Data included CAD, test data, estimated torque / speed, TSR, etc. This data was used to design a generator with a 2 meter diameter rated at 20 kW to connect to a 3m x 7m GHT, or an equivalent FloDesign turbine which presents a 5 m diameter to the flow. This is approximately 21 m^2 in cross section. Comparable dynamic performance…

25. 25 | Wind and Water Power Programeere.energy.gov Selection of appropriate topology Induction or Synchronous? (Field winding not reasonable) AF, RF, or TF? Gearbox for speed? (Rim mount) Iron core or coreless (magnet use and detent torque) Pole Count: more poles more voltage more power (balancing act) Cost and manufacturability Selection: RFPM Synchronous as wind is evolving to.

26. 26 | Wind and Water Power Programeere.energy.gov Gearbox Issue Shaft seals are an issue, bow wakes, velocity fluctuations we selected rim mount speed enhancement with 2 m diameter

27. 27 | Wind and Water Power Programeere.energy.gov Generator Topology AF or RF

28. 28 | Wind and Water Power Programeere.energy.gov What others do…

29. 29 | Wind and Water Power Programeere.energy.gov What others do… Air core? Transverse Flux? Weight reduction? Increased magnet use

30. 30 | Wind and Water Power Programeere.energy.gov What others do… SmartMotor Claims: concentrated windings, higher fill factor, higher efficiency It appears from the description that this generator uses large gauge wire, hand inserted.

31. 31 | Wind and Water Power Programeere.energy.gov What others do… VIEG – Variable Input Electrical Generator This appears to be a “stacked generator.” They appear to be dynamically connecting windings in series at low speed and parallel at high. This appears to be quite costly, like purchasing multiple generators for one site.

32. 32 | Wind and Water Power Programeere.energy.gov Our generator Radial flux, permanent magnet, synchronous, three phase, rim mount (2 meter diameter, 20 kW in 2 m/sec flow) A conventional, buildable, cost effective approach capable of coupling to multiple turbine designs. The design leverages established and simple manufacturing processes.

33. 33 | Wind and Water Power Programeere.energy.gov Concept with Single GHT

34. 34 | Wind and Water Power Programeere.energy.gov Concept with Double GHT

35. 35 | Wind and Water Power Programeere.energy.gov Concept with Ducted In-flow turbine

36. 36 | Wind and Water Power Programeere.energy.gov Electromagnetic Circuit Design

37. 37 | Wind and Water Power Programeere.energy.gov Electromagnetic Circuit Design (cont)

38. 38 | Wind and Water Power Programeere.energy.gov Mechanical Design – Segment Lam

39. 39 | Wind and Water Power Programeere.energy.gov Mechanical Design – Segment Core

40. 40 | Wind and Water Power Programeere.energy.gov Mechanical Design - Magnets

41. 41 | Wind and Water Power Programeere.energy.gov Mechanical Design - Rotor

42. 42 | Wind and Water Power Programeere.energy.gov Mechanical Design - Other

43. 43 | Wind and Water Power Programeere.energy.gov Mechanical Design – Winding Diag.

44. 44 | Wind and Water Power Programeere.energy.gov Other Work Completed Cost Analysis Manufacturability Tooling and Fixturing Requirements Protective Coatings Refer to Final Report

45. 45 | Wind and Water Power Programeere.energy.gov Conclusion Delivered what was proposed… the design of a submersible generator capable of coupling to multiple turbine styles, designed by motor/generator design engineers specifically for MHK Needed: Turbines to move closer to production Diversions to accelerate flow A greater indication of commercial viability

46. 46 | Wind and Water Power Programeere.energy.gov Moving Forward – Latest News…

47. 47 | Wind and Water Power Programeere.energy.gov Moving forward: embracing diversions http://www.youtube.com/watch?v=hEnANV8laRU