5 MW Motor-23-10-003
Transcript of 5 MW Motor-23-10-003
5 MW US Navy MotorClive Lewis
ALSTOM
23 October 2003IEE, London
Approved for public release; distribution is unlimited
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
5 MW Navy MotorTeam
AMSC (Prime contractor):– 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
HTS Ship Propulsion MotorNavy Program Achievements
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
* Funded by the Office of Naval Research** Funded in part by the Office of Naval Research
MotorMotor
RotorRotor
CoolerCooler
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 NmSiemens 400 kW HTS motor: 2500 Nm
Rotor: With cryostat containing high temperature superconducting field coils
Stator: Normal temperature, liquid cooled, airgap winding
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
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 Successful rotor field winding testing has validated HTS field winding and its cooling system. field winding and its cooling system.
Rotor Manufacture
Stator Design
Airgap winding– 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
Stator assembly was designed, fabricated and tested by ALSTOM
Successfully completed construction of air-core stator.Successfully completed construction of air-core stator.
Completed Stator
Coil ManufactureCoil Manufacture
Stator Manufacture
Assembly
Motor assembly and test at ALSTOM Electrical Machines, Rugby UK
Assembly completed January 03
Factory Testing
Extensive factory testing between February 2003 - 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
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
Load Testing
Load testing with 2.5 MW DC machine
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
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
5 MW Navy MotorFuture 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