results of ground-based tests€¦ · 8.6/13 mnm (nominal/peak) flexible coupling hydraulic safety...
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“EcoSwing has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 656024.”
“Herein we reflect only the author's view. The Commission is not responsible for any use that may be made of the information it contains.”
Results of Ground-Based TestsD.8.3 – Public results of ground based tests at Fraunhofer IWESRecapped by Hans Kyling, Fraunhofer IWES
2
Fraunhofer IWES DyNaLab
Load
Application
System
Grid Simulation
DriveGantry Crane Key features:
Drive5° inclined drive train
10/15 MW (nominal/peak) - Twin Synchronous Direct Drive
8.6/13 MNm (nominal/peak)
Flexible coupling
Hydraulic safety coupling (adjustable 8-15 MNm)
Hydraulic load application systemThrust: ± 1900 kN, Radial : ± 2000 kN
Bending: ± 20000 kNm (rotating y-, z-axis)
Dynamic: 0-2 Hz (30% of max. load)
0-g unit for weight compensation (150 to)
Grid simulation10/20/36 kV tappings
44 MVA installed converter capacity
LVRT & HVRT simulation.
• Integration planning of specimen to existing test bench• Cooling• Mechanical adaption• Electrical• Communication specimen <-> test bench• DAQ
• Development of a detailed test plan• Align test requirements with all partners• Needed sensors
• Development of a detailed schedule for the test campaign• Test bench time slot not freely moveable• Clear responsibilities for tasks (nine parties have to coordinate their efforts).
3
Ground test site preparation
Ecoswing test setup
4
Test bench
CoolingDUT
DUT
Transformer
Converter
Rotor adaption
Cooling system, cryo compressors
5
The generator stator and rotor need to be integrated into the DyNaLab cooling system:
Generator requirements:
Stator HX Rotor Compressor
Cooling power [kW]250 + x at rated operation
8 kW per compressor
Water flow [l/min] 635 l/m 9 l/min per compressor)
Water Tin max [°C] < 35 °C < 35 °C
Water Tout max. [°C] 46 °C Tbd
Cooling liquid Water/Glycol Water/Glycol
Cooling mixture 60:40 60:40
Rated pressure drop [bar] 0.5 bar 0.5 bar
• Cooling down period faster then calculated 14 days compared to 18 days
• Good thermal design
• Cooling power of cold heads higher than anticipated
• Overall temperature level was lower then anticipated:
• Thermal design was estimated very conservative
• Cryostat vacuum better then expected
• 2.7∙10-10 bar and self-sustaining
• No pump required during operation
8/27/2019Confidential and Proprietary 6
Cryogenics performance
Lifting
Period
Faster then
computed
Lower then
computed
Aligned test plan
Model validation
Functionaltests
9 partners(expertises,
points ofview)
7
Test plan development
8
Test SpecificationsExample: Efficiency test
9
Mechanical AdaptionTower Adaption
10
Mechanical AdaptionRotor Adaption
Max. desired test load Max. tolerable short time load
Fx (kN) 0 0 (axially free support)
Fy (kN) 0 3,000
Fz (kN) 0 3,000
Mx (kNm) +3,000 / -0 +3,600 /-0
My (kNm) 0 3,800
Mz (kNm) 0 3,800
Table 1: Design Loads for Tower Head Adaptation.
11
Verification on Kinematics of Rotor Adaption – FEM based
Pure driving torque of 3 MNm was applied and resulting torque on driven side added up to 2964 kNm
12
Verification on Kinematics of Rotor Adaption – MBS based
Ramping up speed and torque Ramping up speed and torqueand additional constant shear force
-> Simulation confirms expected behaviour of rotor adaption.
Inneraxial forceson loadcell(s)
• Measurement of input torque next to generator main shaft flange
• Force lever system
• Symmetrical arrangement
• 3 calibrated load cells.
13
Torque measurement system
Verification on compression test bench Verification for tension rod assembly
Validation measurements on load cells
14
Bolt connection through load cell
Tension loading with reference load cell
Clamping factor was experimentally determined for each tension rod.
By measuring the compression load on the cell the rod tension can be determined.
15
Assembly at IWESHall, EcoSwing generator
16
Assembly at IWESLifting, Installation at DyNaLab
✓First excitation up to 40 A
✓Switch to rotary helium supply
✓First excitation up to 285 A
✓First rotation
✓Converter tuning
✓Short circuit test
✓Short circuit and No-Load test
× Quench of one HTS coil
✓First grid connection
✓1 MW power to grid for approx. 1 h with defective coil (120 A rotor current 470 A design current)
17
Conducted tests / occured events
8/27/2019
Some detail findingsPermanent short circuit test
0
100
200
300
400
500
600
700
800
0 20 40 60 80 100 120
Stat
or
curr
ent
(Arm
s)
rotor current (A)
Short Circuit test at 15rpm
Isc = 121 A
8/27/2019
Some detail findingsPermanent short circuit test
No signs of unexpected heating in stator or in bearings
• Stator voltage reached nominal at 260 A rotor current
• The no-load curve does not show any unexpected behavior and is better than the calculated one.
• The reason for this is MAYBE better behavior of stator core when high saturated.
8/27/2019 20
Some detail findingsNo load tests
8/27/2019
Some detail findings Harmonics
0.00000%
0.02000%
0.04000%
0.06000%
0.08000%
0.10000%
0.12000%
0.14000%
0.16000%
0.18000%
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95
VOLTAGE HARMONICS at 71V
0.00000%
0.20000%
0.40000%
0.60000%
0.80000%
1.00000%
1.20000%
1.40000%
1.60000%
1.80000%
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95
VOLTAGE HARMONICS at 690V
• At 10% of Un extremely low harmonics
• 0.16% (H5)
• Reason is the large mechanical airgap, allowed by superconducting technology
• At 100% Un still very low harmonics• 1.6% (H11 grows because of saturation)• Reason for this is MAYBE the extremely
large airgap – which is unique for HTS machines – therefore this is ONLY possible with HTS machine.
• During the test we experienced a quench
• A quench is the transition from superconducting to non-superconducting
• This can be damaging when localized on one hot spot
• In our case this was localized to one of the rotor coils
• There are several possible reasons for this quench like an undetected defect of the superconducting tape or a damage of the coil during mounting
• A detailed investigation is planned
• To avoid further damage we proceeded with partial rotor excitation.
8/27/2019 22
Some detail findingsQuench
8/27/2019 23
Some detail findings Partial power test
0
50000
100000
150000
200000
250000
300000
0 100 200 300 400 500 600
Out
put P
ower
Stator Current Iq
EcoSwing: Power of 1 Converter (of 4)
P (1/4 Converter), 14.5 rpm [W]
Commissioning with converter successful and reached 1 MW
Commutation angle found, dq axis decoupled.
8/27/2019 24
Partial power testRotor adaption load cells unfiltered
The operational loads
measured on the
rods of the rotor
adaption seem to
have a noisy signal,
but…
8/27/2019 25
Partial power testRotor adaption load cells transient unfiltered
For the three
rods average
operational
loads
of 325, 306.5
bzw. 336 kN
are measured.
Additionally there are
amplitudes of 32, 28.5
bzw. 27 kN oscillating
with the rotation
frequency.
8/27/2019 26
Partial power testRotor adaption load cells transient unfilteredOperational Loads in Rod Direction
For the three
rods average
operational
loads
of 325, 306.5
bzw. 336 kN
are measured.
Additionally there are
amplitudes of 32, 28.5
bzw. 27 kN oscillating
with the rotation
frequency.
8/27/2019 27
Partial power testRotor adaption load cells transient unfilteredOperational Loads in Rod Direction
The resulting load
of all load cells
should be 0 in case
of pure torque
transmission.
The resuling forces of
all three load cells
are plotted for a
rotating coordinate
system.in x and y
direction. The raw
data as well as low
pass filtered signal is
given
The resulting shear
force consists of a
two parts:
1) 13.5 kN constant
shear force due
to eccentricity
2) ~27 kN periodic
shear force due
to mass of
adaption
8/27/2019 28
Partial power test: Power measurementsalong drivetrain and its naming
• The power was evaluated at 4 positions along the drivetrain.
• Pos. 1 & 4 based on electrical power measurements
• Pos. 2 & 3 based on strain gauge measurements using the rotational speed to calculate the acting power
8/27/2019 29
Partial power testPower comparison – low pass filtered
Remark:
Drop outs in power
signal on junction box
are due to an error in
the measurement
system
8/27/2019 30
Partial power test Major losses along drivetrain
Test bench
losses
Specimen
losses
8/27/2019 31
Partial power testPower comparison – low pass filtered
Comparing two different
working points one can see
that the mechanical
measurements do not scale
linearly to the electrical
ones.
The measurements
are not linear to each
other for different
power ranges.
Remark:
Drop outs in power
signal on junction box
are due to an error in
the measurement
system
8/27/2019 32
Partial power testPower comparison stable operation – low pass
It is not plausible that the
highest power is
measured for the load cell
position, but the deviation
is within the given
uncertainties.
Power deviations
from power input
at driving engine
in kW
Power deviations
from power input
at driving engine
in %
• Positioning of the sensors • Image of positions 1 & 8 as installed
33
First evaluation of acceleration measurements on stator
• Ramping up to 13 rpm
Two speeds led to a small excitement
• Colormap during power production
Three eigenfrequencies could be identifed.
34
First evaluation of acceleration measurements on stator
600.000.00 Hz
30.00
0.00
s
Tim
e
0.02
0.00
Am
plit
ude (
Peak)
g
489.8229.43
5.96
AutoPow er Gen_Stator_BackPlate:P1:+X WF 61 [0-30 s]
32.000.00 s
Time (Throughput)
13.00
0.00
Am
plit
ude
rpm
1.00
0.00
Am
plit
ude
0.76
0.00
Am
plit
ude
g4.94 10.46
2.52
4.98
F 1002:PECMC.RotSpeed
B2 1019:Gen_Stator_BackPlate:P1:+X only reduced values available
B2 1020:Gen_Stator_BackPlate:P1:+Y only reduced values available
B2 1021:Gen_Stator_BackPlate:P1:+Z only reduced values available
Superconductivity has matured sufficiently that we can follow an ambitious plan:
• Design, develop and manufacture a full scale multi-megawatt direct-drive superconducting wind generator
• Execute ground-based testing in Fraunhofer IWES’ DyNaLab
• Install and operate this superconducting drive train on an existing modern wind turbine in Thyborøn, Denmark(3 MW Class, 14 rpm, 128 m rotor)
• Prove that a superconducting drive train is cost-competitive.
The consortium and its plan
✓
✓
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