SuperconductivityforLargeScaleWindTurbines-F

NextGenerationDriveTrainSuperconductivityforLarge-ScaleWindTurbines*AppliedSuperconductivityConference,Portland,OregonOctober11th,2012R.Fair,W.Stautner,M.Douglass,R.Rajput-Ghoshal,M.Moscinski,P.Riley,D.Wagner,J.Kim,S.Hou,F.Lopez,K.Haran,J.Bray,T.Laskaris,J.RochfordGeneralElectric-GlobalResearch,Niskayuna,NY,USAR.DuckworthOakRidgeNationalLaboratory,OakRidge,TN,USA.*ThismaterialisbasedonworksupportedbytheDepartmentofEnergyunderAwardNumberDE-EE0005143.AcknowledgementsarealsoduetoTheOakRidgeNationalLaboratoryfortheircontributiontothisproject.2Oct11th2012ProjectObjectivesTheprimaryobjectiveoftheprojectwastoapplylowtemperaturesuperconductingtechnologytothedesignofadirect-drivewindturbinegeneratoratthe10MWpowerlevelinordertoreducetheCostofEnergy(COE).The6monthprojectfocusedonthedesignofthegenerator,anevaluationofthecommercialviabilityofthedesigntogetherwithanidentificationofhighriskcomponents.3Oct11th2012Howcanwegettoacommerciallyviableproductasquicklyandaspragmaticallyaspossible?Usereadilyavailable,cost-effectiveprovensuperconductorLTSReduceriskatthepre-designstagee.g.eliminatethecryogentransfercouplingStationaryfieldUtilizeGEHealthcareMRIcoolingtechnologyknow-howUtilizeconventionalmanufacturingmaterialsandexistingproductionprocessesUtilizeGE’sextensiveknowledgeofwindsystemintegrationProjectScope4Oct11th2012Generatorexternalview5Oct11th2012KeyGeneratorDimensions6Oct11th2012Totalweightofgenerator=93metrictonnes(excludingbearings,shaftsandventilationsystem)Totalweightofgenerator=143metrictonnes(includingbearings,shaftsandventilationsystem)Cross-sectionalviewofthegenerator7Oct11th2012Opencircuitfluxdensityplot(Tesla)ParameterValueRatedPower10MWRatedSpeed10rpmRatedtorque10MNmRatedVoltage3300Vline-lineRatedCurrent1750ARatedPowerFactor1.0FullLoadEfficiency95-96%PhysicalAirgaplength19mmNo.ofpoles/No.ofslots36/648ArmatureWindingType3phase,2layer,lap,formwoundInsulationClassF(withClassBtemperaturerise)SCFieldMMF928000AT/poleArmatureCoolingAxialaircooledthruairgapandyokeGeneratorfinaldesignparametersFigureofMerit10MWSCGeneratorConventionalPMGeneratorIncreasewithSCShearStress179kPa85kPa2XTorqueDensity(EMonly)197Nm/kg94Nm/kg2XTorqueDensity(Drivetrain)92Nm/kg44Nm/kg2XPeakFaultCurrent15p.u.(L-L-L)4p.u.4XPeakFaultTorque12p.u.(L-L)2p.u.6X8Oct11th2012GeneratorLoadCondition10MW@10rpmArmwindingDCLoss363kWArmatureACLoss56kWArmatureYokeLoss5.7kWArmatureTeethLoss5.6kWArmatureCoreClampLoss2.1kWFieldACLoss(incl.vessels)2.6kWArmatureSlipRingLoss4.6kWFrictionandWindagenegligibleCryocoolerpower(3)22.5kWCoolingAirBlowers(6)39kWTotalLoss501kWEfficiency95.0%Generatorlossesandefficiency9Oct11th2012CurrentDesign:•No.ofsliprings=4•SlipringOD=3m•No.ofcarbonbrushesperslipring=30•Currentperbrush=60A•Rotationalspeed=10rpm•Totaloperationalloss@10MW=4.6kW•Air-cooledassembly•Brushwearperyear2mm@10rpmArmatureslipringdesign10Oct11th2012-Sixairblowersaremountedtothefieldsupportplate.-Theyarebeltdrivenunitswith5hp,3600rpm,460v,3ph,60Hzmotors,housingdrains,motorcovers,shaftseal,beltsanddrives.-Theweightofeachunitwithaluminumwheel,housingandmotorpedestalisapproximately251lbs.Theestimatedinputpowerforsixblowersis~39kW.11Oct11th2012GeneratorcoolingconfigurationMagneticteethNon-magneticteethHotspotsinthearmatureandvacuumchamberwallformagneticteethareslightlylowerthanforthenon-magneticteethdesignoptionHotspottemperatureofthevacuumwalliswellbelowthethermalradiationlimitof80oCMagneticvsNon-magneticarmatureteeth12Oct11th20124blowers6blowers4blowers5blowersThefinaldesignforthecoolingofthearmaturesettledupon2rowsofcoolingholeswithatotalof6air-blowersprovidingamoreuniformairflowdistributionandameasureofredundancyArmaturecoolingductdesign13Oct11th2012•Optimizationparameters–Widthofthecoil–Heightofthecoil–Endradiusofthecoil–Operatingcurrentinthecoil–Shortsamplepercentageforcoils–Currentsharingtemperaturefortheconductor–Asufficientmarginisrequiredforthestableoperationofthecoils.Currentsharingtemperaturedependsonthemaximumfieldinthecoil,criticalcurrentatmaximumfield,ratioofoperatingcurrenttocriticalcurrentatmaximumfieldandratioofmaximumfieldinthecoiltocriticalfieldoftheconductorSCcoiloptimization14Oct11th2012SCcoilfinaldesignparameters15Oct11th2012ParameterValueTypeofconductorusedCu-(NbTi)Cu:SC1.5Barediameterofconductor(mm)1.00Insulateddiameterofconductor(mm)1.05Numberoffilaments7400Filamentdiameter(micron)7.5ParameterValueCoiltypeRacetrackCoilwidth(mm)35.00No.oflayersincoilwidth39Coilheight(mm)101.60No.ofturnsincoilheight97Coillengthstraight(mm)1879.60CoilInnerWidth(mm)261.01Endradius(mm)124.58TypeofconductorusedCu-(NbTi)Barediameterofconductor(mm)1.00Insulateddiameterofconductor(mm)1.05Operatingcurrent(Amp)276.86Totalampereturns(A)928000Maximumfieldinthecoil(T)7.35Criticalcurrentatthemaximumfield(Amp)466.75Shortsamplepercentage(%)59.96Criticaltemperature(K)6.08Storedenergyofthesystem(MJ)40.6Inductanceofallthecoils(H)1059Totalconductorusedfor36coils(km)720Totalestimatedweightofthecoils(kg)3840LossContribution1.Lossduringoperationa.Lossesduetofieldcurrentboost