The Status of HTS The Status of HTS Ship Propulsion Motor DevelopmentsShip Propulsion Motor Developments

S. Kalsi, B. Gamble, G. Snitchler and S. Ige AMSC

Panel: Superconductor Rotating Machines for Ship and Aircraft Panel: Superconductor Rotating Machines for Ship and Aircraft ApplicationsApplications

IEEE PES Meeting, Montreal, CanadaIEEE PES Meeting, Montreal, Canada20 June 2006

OutlineOutline

Introduction Wire technology

BackgroundPrior machines

36.5 MW36.5 MW basic characteristicsSubsystem descriptionsProgress and status

Other Opportunities CondensersGeneratorsDegaussing

Summary and Power Density Comparison

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentIntroduction Introduction –– Machine TopologyMachine Topology

Multiphase Synchronous MachineMedium voltageConventional driveAdjustable excitationLarge airgapLow synchronous reactanceEfficient

RotorHTS field windingVacuum insulatedCooling in stationary reference frameCOTS rotor cooling hardware

StatorDielectric oil coolingLitz copper coilsComposite teethBack-iron return flux path

BearingsRotor poles

Back iron

Stator coils

Vacuumchamber

Housing

EM shield

Brushlessexciter

Heliumtransfercoupling

BearingsRotor poles

Back iron

Stator coils

Vacuumchamber

Housing

EM shield

Brushlessexciter

Heliumtransfercoupling

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentIntroduction Introduction –– High Temperature Superconductor WiresHigh Temperature Superconductor Wires

0.2mm0.2mm

BiBi22SrSr22CaCa22CuCu33OO YY11BaBa22CuCu33OO

4.4mm4.4mm

First generation (1G) HTS wire Second generation (2G) HTS wire - 344 Superconductors

344 superconductors are designed to be a low cost, form-fit-function replacement For 1G wire – both available for sale

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentIntroduction Introduction –– High Temperature Superconductor WiresHigh Temperature Superconductor Wires

2G Wire (344): 125A, 4.4 mm width1G Wire: 125A, 4.4 mm width

0 2 4 6 81

10

100

1G-64K1G-77K

1G-35K

2G-40K

2G-65K

2G-77KCrit

ical

Cur

rent

(A)

Applied Field (T)

H//c

2G wire performance in applied field equals or exceeds 1G wire

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentBackground Background –– Prior HTS Electric MachinesPrior HTS Electric Machines

Early MachinesAMSC and RockwellFractional HP through 1000 HP at 1800 rpm LN2 and helium gas coolingAir cooled armatures

5,000 HP MotorAMSC fabricated rotor tested at Electric MachinesWater-cooled Litz ArmatureNeon-cooled rotor

5 MW MotorAMSC and ALSTOMDielectric oil cooled Litz ArmatureHelium gas cooled rotorExtensively tested by CAPS for ONR

3,000 ft-lbf

15,000 ft-lbf

150,000 ft-lbf

Developments led to the 2,100,000 ft-lbf 36.5MW ONR Motor

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor Development5 MW AMSC/ONR Subscale Demonstration5 MW AMSC/ONR Subscale Demonstration

Joint AMSC/ALSTOM project sponsored by ONRAMSC

Rotor Cryorefrigeration systemExcitation system

ALSTOM in Rugby, UK & Nancy, FranceStatorMotor assembly & FAT

FAT completed 2003—50% power, 100% torqueIEEE-115 testingValidated armature temperature riseDemonstrated mechanical capability

Full-power testing at Florida State University Center for Advanced Power Systems (CAPS)

5 MW demonstrated at 230 rpmLoad & ship mission profile simulation Motor to NAVSSES, Philadelphia in 2005

Power: 5 MW Torque: 153,000 ft-lbsSpeed: 0-230 rpm Volts: 4160, 3Ø, 0-11.5 HzField: 137 A, 30K Refrigeration: Gaseous HeArmature: Liquid cooled

5 MW Motor Testing At CAPS5 MW Motor Testing At CAPS

2.5 MW Load Motors

5 MW HTSMotor

5 MW HTS Motor delivered rated power and torque

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentONR ProgramONR Program

Objective: Develop a Full Scale, High Power Density, Lightweight, Advanced 36.5 MW Propulsion Motor and Drive System compatible with naval applications Contract Awarded to AMSC February 2003Design Drivers: Low Weight, High Power Density, Improved Efficiency and Low Noise Detail Design Completed October 2004 –Design meets MIL-S-901D Shock and DD(X) AcousticsFactory Acceptance Testing (Marine Systems) completed in 4th Quarter 2006

4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9

Phase A - Preliminary Design

Phase B - Detailed Design

Phase C - Manufacture and FAT

2003 2004 2005 2006

DDR Motor

Delivery

Design leverages features successfully tested on 5 MW HTS motor

10

PDR

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentSubsystemsSubsystems

Drive – Robicon/Siemens

MotorRotor – AMSCStator – Electric MachinesFrame – NGES-MS

Rotor Cooling - AMSC

Stator Cooling Skid NGSS

Stator Lube Skid - NGSS

System Controller - AMSC

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentComponents during ManufactureComponents during Manufacture

Rotor Complete and Delivered to NGC Motor Assembly Site

Refrigerator Complete and Delivered

Stator Winding Process Nearing Completion

Frame is Currently Being Installed at NGC Philadelphia Test Facility

Many components have already passed factory acceptance tests

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentCalculated Characteristic ParametersCalculated Characteristic Parameters

• 36.5MW motor was designed based on the analysis codes used for the 5,000 HP and 5 MW motors.

• Calculated parameters will be validated in testing later this year per IEEE 115 no-load test procedures at NGC Philadelphia

Rating 36.5 MW

Vphase 5.8 kV

Speed 120 rpm

Xd 0.368 pu

Xdstr 0.32 pu

Xdstr 0.243 pu

η (motor) 97.1 %

η (w ancillaires) 96.9 %

Factory testing will occur over the summer with a September completion

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentInitial Factory Test ResultsInitial Factory Test Results

• Integrated Rotor Field Winding Test

- Rotor- Exciter- Refrigeration

• Integrated Test Results- Thermal Steady State- Temperature Below Design

Point- Exciter Tests Included

• Active Field Adjustment

• Operation to 113% current

Rotor+HTS Poles+Rotor Cooler+Exciter designs verified in factory testing

Time (hrs)

Fiel

d C

urre

nt (p

.u.)

Tem

pera

ture

(K)

Other HTS Technology ApplicationsOther HTS Technology ApplicationsCondensers, GeneratorsCondensers, Generators

6.0 m3.7 m

4.4

m

1

Conventional

HTS

• Two power ranges of interest:- 40 – 50 MW to package with either LM6000

or RR MT-30 uprated turbines for main turbine generator

- 14 MW to package with LM1600 gas turbine and up-rate the auxiliary GT capability

• Either program ~30 month development• Permits transformerless drive systems

saving several times the generator weight

SuperVARSuperVAR®® Installation Installation on TVA Gridon TVA Grid

HTS generator technologies build on utility grid experience

40 MW HTS GeneratorCompared to

DD(X) 36 MW Generator

DD(X) EDM Generator @ 82 TonsHTS Generator @ 37 Tons

HTS Generators offer impressive weight and size advantage

36.5 MW HTS Propulsion Motor Development36.5 MW HTS Propulsion Motor DevelopmentSummary and Power Density ComparisonSummary and Power Density Comparison

HTS Motors are multi-phase synchronous machines with active field control, large airgap, and the flexibility to utilize a variety of drives.HTS wire used in the actively cooled rotor is presently 1G; starting migration to 2G wireThe 36.5 MW motor is based on experience from multiple HTS electric machines.The ONR 5 MW motor provided the basis for the components used in the 36.5 MW motor.The program is on track to deliver a high power density75 metric ton motor to the Navy in September of this year.The rotor has been tested and the stator assembly is almost complete.No load testing at the NGC Philadelphia facility this summer.HTS is also applicable to generators.

0204060

80100120140160180200

0.010 0.100 1.000 10.000Torque (MN-m)

Wei

ght (

Tonn

e)

40 MW HTS Generator Estimate

HTS 5 kHP1800 rpm HTS 5 MW 230 rpm

HTS 36.5 MW 120 rpm

AIM

36 MW 2-pole Conv. Generator

HTS motors offer the next generation in power density for naval propulsion

TM