Presentation on theme: "1 | Program Name or Ancillary Texteere.energy.gov Water Power Peer Review Schneider Linear hydroEngine ™ (SLH) Timing Belt Powertrain PI: Abe Schneider."— Presentation transcript:
1 | Program Name or Ancillary Texteere.energy.gov Water Power Peer Review Schneider Linear hydroEngine ™ (SLH) Timing Belt Powertrain PI: Abe Schneider Natel Energy, Inc November, 2011 FY 11 CH FOA Topic 1.1 Sustainable Small Hydropower, Innovative System Testing
2 | Wind and Water Power Programeere.energy.gov Purpose, Objectives, & Integration Project Purpose: –Develop a new high performance powertrain for the SLH utilizing a carbon-fiber reinforced timing belt Relation to program objectives: –Development of an enabling technology for efficient and low cost small hydropower that can be quickly and efficiently deployed in low head/low flow existing waterways and constructed waterways. –Creation of advanced SLH powertrain manufacturing methods and production of longterm mechanical performance test data, thus advancing the industry’s expertise in engineering, design, installation, and performance evaluation of low-head hydropower technology. –Reduction of LCOE from low-head and constructed waterway projects built with hydroEngines™ to less than $0.07 per kWh.
3 | Wind and Water Power Programeere.energy.gov Technical Approach 1.Complete design and testing of belt-type SLH powertrain components at 50 kW- and 500 kW-scales. –Component testing allows for cost effective, rapid iteration through prototypes; finite element modeling can help reduce required number of physical prototypes. High-torque dynamometer endurance tests will enable evaluation of tooth/sprocket wear and effects of environmental conditions. 2.Phase I, System Endurance Testing: Integrate v1 belt/blade attachment design into small-scale (50 kW) SLH model and conduct long-duration laboratory testing, across a full range of potential operating scenarios. –Ensure technology meets performance specifications and performs as designed before full-scale commercial development. 3.Phase II, System Endurance Testing: Integrate v2 belt/blade attachment design into a 50 kW SLH model, and conduct long- duration laboratory testing. –Integrate lessons-learned from Phase I testing; ensure improved technology meets performance specifications and performs as designed before full-scale commercial development. Instron testing of belt coupon Endurance testing setup at Alden
4 | Wind and Water Power Programeere.energy.gov Technical Approach 4. Design-For-Manufacture, both 50 kW and 500 kW scale Ensure manufacturability of powertrain solution, minimizing cost while maintaining performance; prepare powertrain for commercialization. 5. Calculate LCOE of SLH, as a consequence of new belt powertrain. –Timing belt powertrain will substantially alter the mechanical architecture (and thus, capital cost structure) of the hydroEngine™, as well as change its operation and maintenance profile. Historic LCOE models must be updated accordingly.
5 | Wind and Water Power Programeere.energy.gov Plan, Schedule, & Budget Schedule: Initiation date: Project awarded September, 2011 (project initiation will occur after contract negotiations are completed) Planned completion date: Project completion expected in 2012 (subject to final contract negotiations) YearProject ObjectiveActivities 2011 “v1” belt attachment recommendation Component design & testing, both SLH10 & SLH100 scale. “v1” belt attachment recommendationDynamometer, fatigue tests 2012 Phase I: endurance testing Install, commission, conduct tests, inspect, generate “v2” design recommendation. Phase II: endurance testing Redesign as necessary, modify lab-model SLH10, reinstall, run endurance tests & inspections. Design-for-manufacturingImprove design based upon DFM exercise. LCOE updateUpdate LCOE calculations Prepare delivery of SLH100 (500 kW scale) belt prototype to irrigation district pilot customers. Budget: DOE anticipates awarding approximately $300k for this project, with an awardee cost share of approximately $153k (subject to final contract negotiations)