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*
Rotor
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
Motor
Preparing to conduct land based testing

* Funded by the Office of Naval Research

** Funded in part by the Office of Naval Research
 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 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