5 MW US Navy Motor

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• 5 MW US Navy Motor
• Clive Lewis
• ALSTOM
• 23 October 2003
• IEE, London
• Approved for public release distribution is
  unlimited

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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

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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

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HTS Ship Propulsion MotorNavy Program
Achievements
Cooler
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
Rotor
Motor
Funded by the Office of Naval Research
Funded in part by the Office of Naval Research
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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

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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

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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.
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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

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Stator Manufacture

• Stator assembly was designed, fabricated and
  tested by ALSTOM

Coil Manufacture
Completed Stator
Successfully completed construction of air-core
stator.
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Assembly

• Motor assembly and test at ALSTOM Electrical
  Machines, Rugby UK
• Assembly completed January 03

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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

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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

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Load Testing

• Load testing with 2.5 MW DC machine

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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

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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

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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