Transcript Document

5 MW US Navy Motor
Clive Lewis
ALSTOM
23 October 2003
IEE, 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 Motor
Team

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 Motor
Navy Program Achievements
Key achievements of 2000*
Cooler
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
Rotor
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
Motor
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 Nm
Siemens 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
Rotor Manufacture





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
field winding and its cooling system.
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 Manufacture

Stator assembly was
designed, fabricated and
tested by ALSTOM
Coil Manufacture
Completed Stator
Successfully completed construction of air-core stator.
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 Motor
Future 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 NSWCCDSSES 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