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