The Status of HTS Ship Propulsion Motor Developments

Transcription

1 The Status of HTS Ship Propulsion Motor Developments S. Kalsi, B. Gamble, G. Snitchler and S. Ige AMSC Panel: Superconductor Rotating Machines for Ship and Aircraft Applications IEEE PES Meeting, Montreal, Canada 20 June 2006

2 Outline Introduction Wire technology Background Prior machines 36.5 MW 36.5 MW basic characteristics Subsystem descriptions Progress and status Other Opportunities Condensers Generators Degaussing Summary and Power Density Comparison

3 Introduction Machine Topology Multiphase Synchronous Machine Medium voltage Conventional drive Adjustable excitation Large airgap Low synchronous reactance Efficient Rotor HTS field winding Vacuum insulated Cooling in stationary reference frame COTS rotor cooling hardware Stator Dielectric oil cooling Litz copper coils Composite teeth Back-iron return flux path Brushless exciter Helium transfer coupling Vacuum chamber Back iron Rotor poles Bearings Housing Stator coils EM shield

4 Introduction High Temperature Superconductor Wires Bi 2 Sr 2 Ca 2 Cu 3 O Y 1 Ba 2 Cu 3 O 0.2mm 4.4mm First generation (1G) HTS wire Second generation (2G) HTS wire Superconductors 344 superconductors are designed to be a low cost, form-fit-function replacement For 1G wire both available for sale

5 Introduction High Temperature Superconductor Wires 1G Wire: 125A, 4.4 mm width 2G Wire (344): 125A, 4.4 mm width Critical Current (A) G-77K 1G-64K 1G-35K 2G-77K 2G-40K 2G-65K 1 H//c Applied Field (T) 2G wire performance in applied field equals or exceeds 1G wire

6 Background Prior HTS Electric Machines Early Machines AMSC and Rockwell Fractional HP through 1000 HP at 1800 rpm LN 2 and helium gas cooling Air cooled armatures 5,000 HP Motor AMSC fabricated rotor tested at Electric Machines Water-cooled Litz Armature Neon-cooled rotor 5 MW Motor AMSC and ALSTOM Dielectric oil cooled Litz Armature Helium gas cooled rotor Extensively 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

7 5 MW AMSC/ONR Subscale Demonstration Joint AMSC/ALSTOM project sponsored by ONR AMSC Rotor Cryorefrigeration system Excitation system ALSTOM in Rugby, UK & Nancy, France Stator Motor assembly & FAT FAT completed % power, 100% torque IEEE-115 testing Validated armature temperature rise Demonstrated mechanical capability Full-power testing at Florida State University Center for Advanced Power Systems (CAPS) 5 MW demonstrated at 230 rpm Load & ship mission profile simulation Motor to NAVSSES, Philadelphia in MW HTS Motor delivered rated power and torque Power: 5 MW Torque: 153,000 ft-lbs Speed: rpm Volts: 4160, 3Ø, Hz Field: 137 A, 30K Refrigeration: Gaseous He Armature: Liquid cooled 5 MW Motor Testing At CAPS 2.5 MW Load Motors 5 MW HTS Motor

8 ONR 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 2003 Design 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) Acoustics Factory Acceptance Testing (Marine Systems) completed in 4 th Quarter Phase A - Preliminary Design PDR Phase B - Detailed Design DDR Phase C - Manufacture and FAT Motor Delivery 10 Design leverages features successfully tested on 5 MW HTS motor

9 Subsystems Drive Robicon/Siemens Motor Rotor AMSC Stator Electric Machines Frame NGES-MS Rotor Cooling - AMSC Stator Cooling Skid NGSS Stator Lube Skid - NGSS System Controller - AMSC

10 Components 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

11 Calculated 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 V phase Speed X d X dstr X dstr 5.8 kv 120 rpm pu 0.32 pu pu η(motor) 97.1 % η(w ancillaires) 96.9 % Factory testing will occur over the summer with a September completion

12 Initial 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 Field Current (p.u.) Time (hrs) Rotor+HTS Poles+Rotor Cooler+Exciter designs verified in factory testing Temperature (K)

13 Other HTS Technology Applications Condensers, Generators Conventional m 3.7 m HTS 6.0 m Two power ranges of interest: 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 40 MW HTS Generator Compared to DD(X) 36 MW Generator DD(X) EDM 82 Tons HTS 37 Tons SuperVAR Installation on TVA Grid HTS generator technologies build on utility grid experience HTS Generators offer impressive weight and size advantage

14 Summary 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 wire The 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. Weight (Tonne) MW HTS Generator Estimate HTS 5 khp1800 rpm AIM 36 MW 2-pole Conv. Generator HTS 36.5 MW 120 rpm HTS 5 MW 230 rpm Torque (MN-m) HTS motors offer the next generation in power density for naval propulsion

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