Presentation on theme: "Approved for public release; distribution is unlimited"— Presentation transcript:
1Approved for public release; distribution is unlimited 5 MW US Navy MotorClive LewisALSTOM23 October 2003IEE, LondonApproved for public release; distribution is unlimited
25 MW Navy Motor for ONRSeventeen month contract awarded 14 February 2002 to complete design of 5 MW motor as a technology demonstrator motor for a full-size HTS motorFabrication and factory testing of 5 MW motorFabrication and factory testing of COTS drive VDM5000Perform factory testing on the motor and drive separately and then as an integrated system to validate methods for predicting machine performanceDemonstrate and characterize HTS marine motor performance as an integrated motor and drive systemDeliver the system to ONR by 14 July 2003
35 MW Navy Motor Team AMSC (Prime contractor): ALSTOM Power Conversion: Design, fabrication and testing of rotorDesign, fabrication and testing of rotor cooling systemOverall motor electromagnetic designALSTOM Power Conversion:Design (electromagnetic and mechanical), Structure borne noise modeling, fabrication and testing of the stator, frame and bearingsMotor assemblyVDM 5000 COTS driveFactory testing of motor, drive and combined systemNorthrop Grumman Ship Systems:Shipbuilding and integration expertise
4HTS Ship Propulsion Motor Navy Program Achievements CoolerKey achievements of 2000*Defined specifications for the 5 MW motor for component developmentIdentified critical components for developmentPerformed key component development workKey achievements of 2001*Designed 5 MW motorStarted manufacturing 5 MW motor componentsKey achievements of 2002**Completed rotor and stator fabrication of 5 MW motorKey achievements of 2003**Assembled motor and performed factory testingDelivered 5 MW motorPreparing to conduct land based testingRotorMotor* Funded by the Office of Naval Research** Funded in part by the Office of Naval Research
55 MW Motor Specification Application: Ship propulsionType: SynchronousOutput: 5000 kW at 230 rpm,Rated torque: 207,000 NmComparisons AMSC 5000 hp HTS motor: 19,800 Nm Siemens 400 kW HTS motor: 2500 NmRotor: With cryostat containing high temperature superconducting field coilsStator: Normal temperature, liquid cooled, airgap winding
6Advantages of HTS Motors for Naval Ship Propulsion Applications High power density in low speed, high torque motorsHigh efficiency, particularly at part loadLow noise
7Rotor ManufactureThe rotor and associated hardware was tested at AMSC including:Excitation up to full currentRefrigeration operating temperature in full and degraded modesField winding up to full design currentRotor balanced in cold state at ALSTOMSuccessful rotor field winding testing has validated HTS field winding and its cooling system.
8Stator Design Airgap winding Liquid dielectric cooled Enables operation at higher flux density than a winding with iron teeth - hence greater outputStator coils must be made from transposed litz wire to avoid large eddy current lossesTorque is exerted on the stator conductors rather than the iron teeth - this torque must be supported and transmitted to the stator frameLiquid dielectric cooledGood heat transfer for high power densityGood electrical insulation performance
9Stator Manufacture Coil Manufacture Completed Stator Stator assembly was designed, fabricated and tested by ALSTOMCoil ManufactureCompleted StatorSuccessfully completed construction of air-core stator.
10AssemblyMotor assembly and test at ALSTOM Electrical Machines, Rugby UKAssembly completed January 03
11Factory TestingExtensive factory testing between February June 2003Testing in two stagesNo load open circuit and short circuit testingStandard synchronous motor testing to IEEE 115Load testing with VDM 5000 drive up to rated motor torqueTesting carried out at ALSTOM, Rugby by a joint ALSTOM and AMSC team
12No Load Testing Open Circuit and Short Circuit testing to IEEE 115 Determine motor parametersDetermine motor efficiency under full load and part load conditionsDetermine motor temperature rise under full load conditionsMotor achieved or exceeded design targetsCompleted March 2003
14Load TestingMotor driven by VDM5000 COTS PWM Drive to demonstrate and characterize the HTS marine motor performance as an integrated motor and drive systemLoaded 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 completedStructure borne noise testing confirmed low noise operationStray flux levels comparable with conventional motorsONR witness testing completed June 2003
15Factory Testing Summary Heat Run at rated torque, rated stator current concluded motor will deliver the rated torque with temperature rise predicted from no load testsDemonstrated mechanical capability of rotor and stator construction to deliver continuous rated torqueThe basic rotor and stator technology has worked well and without any problemsNo redesign or rework of the rotor or stator was required during or following the testing5 MW Motor and Drive were delivered to ONR at the Center for Advanced Power Systems (CAPS) on 22 July 2003
165 MW Navy Motor Future Plans ONR selected CAPS at Florida State University to perform the initial land-based tests of the 5 MW motorThe 5 MW motor and drive will be integrated in late 2003 for no-load testingThe Load machine is on order allowing system integration and load tests to start in February 2004The 5 MW Motor and Drive will be moved to NSWCCD-SSES Philadelphia in late of 2004 for further testing by Navy personnelThe successful operation of the largest HTS propulsion motor will be demonstrated through these differing test scenarios providing the Navy with hands-on experience