1. Approved for public release; distribution is unlimited
5 MW US Navy Motor
Clive Lewis
ALSTOM
23 October 2003
IEE, London
Approved for public release; distribution is unlimited

2. 5 MW Navy Motor for ONR
Seventeen month contract awarded 14 February 2002 to complete design of 5 MW motor as a technology demonstrator motor for a full-size HTS motor
Fabrication and factory testing of 5 MW motor
Fabrication and factory testing of COTS drive VDM5000
Perform factory testing on the motor and drive separately and then as an integrated system to validate methods for predicting machine performance
Demonstrate and characterize HTS marine motor performance as an integrated motor and drive system
Deliver the system to ONR by 14 July 2003

3. 5 MW Navy Motor Team AMSC (Prime contractor): ALSTOM Power Conversion:
Design, fabrication and testing of rotor
Design, fabrication and testing of rotor cooling system
Overall motor electromagnetic design
ALSTOM Power Conversion:
Design (electromagnetic and mechanical), Structure borne noise modeling, fabrication and testing of the stator, frame and bearings
Motor assembly
VDM 5000 COTS drive
Factory testing of motor, drive and combined system
Northrop Grumman Ship Systems:
Shipbuilding and integration expertise

4. HTS Ship Propulsion Motor Navy Program Achievements
Cooler
Key achievements of 2000*
Defined specifications for the 5 MW motor for component development
Identified critical components for development
Performed key component development work
Key achievements of 2001*
Designed 5 MW motor
Started manufacturing 5 MW motor components
Key achievements of 2002**
Completed rotor and stator fabrication of 5 MW motor
Key achievements of 2003**
Assembled motor and performed factory testing
Delivered 5 MW motor
Preparing to conduct land based testing
Rotor
Motor
* Funded by the Office of Naval Research
** Funded in part by the Office of Naval Research

5. 5 MW Motor Specification
Application: Ship propulsion
Type: Synchronous
Output: 5000 kW at 230 rpm,
Rated torque: 207,000 Nm
Comparisons AMSC 5000 hp HTS motor: 19,800 Nm Siemens 400 kW HTS motor: 2500 Nm
Rotor: With cryostat containing high temperature superconducting field coils
Stator: Normal temperature, liquid cooled, airgap winding

6. Advantages of HTS Motors for Naval Ship Propulsion Applications
High power density in low speed, high torque motors
High efficiency, particularly at part load
Low noise

7. Rotor Manufacture
The rotor and associated hardware was tested at AMSC including:
Excitation up to full current
Refrigeration operating temperature in full and degraded modes
Field winding up to full design current
Rotor balanced in cold state at ALSTOM
Successful rotor field winding testing has validated HTS field winding and its cooling system.

8. Stator Design Airgap winding Liquid dielectric cooled
Enables operation at higher flux density than a winding with iron teeth - hence greater output
Stator coils must be made from transposed litz wire to avoid large eddy current losses
Torque is exerted on the stator conductors rather than the iron teeth - this torque must be supported and transmitted to the stator frame
Liquid dielectric cooled
Good heat transfer for high power density
Good electrical insulation performance

9. Stator Manufacture Coil Manufacture Completed Stator
Stator assembly was designed, fabricated and tested by ALSTOM
Coil Manufacture
Completed Stator
Successfully completed construction of air-core stator.

10. Assembly
Motor assembly and test at ALSTOM Electrical Machines, Rugby UK
Assembly completed January 03

11. Factory Testing
Extensive factory testing between February June 2003
Testing in two stages
No load open circuit and short circuit testing
Standard synchronous motor testing to IEEE 115
Load testing with VDM 5000 drive up to rated motor torque
Testing carried out at ALSTOM, Rugby by a joint ALSTOM and AMSC team

12. No Load Testing Open Circuit and Short Circuit testing to IEEE 115
Determine motor parameters
Determine motor efficiency under full load and part load conditions
Determine motor temperature rise under full load conditions
Motor achieved or exceeded design targets
Completed March 2003

13. Load Testing
Load testing with 2.5 MW DC machine

14. Load Testing
Motor driven by VDM5000 COTS PWM Drive to demonstrate and characterize the HTS marine motor performance as an integrated motor and drive system
Loaded by 2.5 MW DC machine up to rated torque at half speed, and half load at full speed. Demonstrated mechanical capability of rotor and stator construction to deliver continuous rated torque.
Reliability testing to repeatedly cycle the motor up to rated torque and rated temperature successfully completed
Structure borne noise testing confirmed low noise operation
Stray flux levels comparable with conventional motors
ONR witness testing completed June 2003

15. Factory Testing Summary
Heat Run at rated torque, rated stator current concluded motor will deliver the rated torque with temperature rise predicted from no load tests
Demonstrated mechanical capability of rotor and stator construction to deliver continuous rated torque
The basic rotor and stator technology has worked well and without any problems
No redesign or rework of the rotor or stator was required during or following the testing
5 MW Motor and Drive were delivered to ONR at the Center for Advanced Power Systems (CAPS) on 22 July 2003

16. 5 MW Navy Motor Future Plans
ONR selected CAPS at Florida State University to perform the initial land-based tests of the 5 MW motor
The 5 MW motor and drive will be integrated in late 2003 for no-load testing
The Load machine is on order allowing system integration and load tests to start in February 2004
The 5 MW Motor and Drive will be moved to NSWCCD-SSES Philadelphia in late of 2004 for further testing by Navy personnel
The successful operation of the largest HTS propulsion motor will be demonstrated through these differing test scenarios providing the Navy with hands-on experience