Cryogenics Day Converteam - Research Councils UK
Transcript of Cryogenics Day Converteam - Research Councils UK
High Temperature Superconductivity (HTS) Technology Requirements
Clive Lewis, Advanced Technology group
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Contents
Introduction to Converteam
HTS Direct Drive Wind Turbine Generator
OPT Powerbuoy – HTS Linear Wave Generator
POSEEIDON – Electric ship propulsion utilising HTS technology
HYDROGENIE – HTS Hydroelectric Generator
Infrastructure requirements
Key enablers for HTS rotating machinery
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CONVERTEAM AT A GLANCE 1/2
Power generation Power transmission& distribution
Converteam
Marine
Industry
O&G
Converteam: a new name for a company with more than 100 years experience in power conversion
Converteam is an engineering company providing customised solutions and systems converting electrical energy into productive performance
Energy
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CONVERTEAM AT A GLANCE 2/2
Converteam provides solutionssystems
These solutions are made of built around 3 core components:
■ Rotating Machines■ Variable Speed Drives■ Process automation & control
We address 4 major markets:■ Marine■ Oil & Gas■ Energy (Mainly renewable)■ Industry
Our scope covers consulting, design, manufacturing, system integration, installation, commissioning and a broad range of services
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History of HTS Development in Converteam
Rotating (and linear) electrical machines using HTS field windings. HTS coils with DC current working in medium strength magnetic fields (2-5 T)
■ 1999 – 2003■ Partner with American Superconductor (AMSC) in design study for
25 MW HTS motor for US Navy. Design, manufacture and test of 5 MW, 230 rpm motor.
■ 2004 – 2005■ Internal design and feasibility studies into the application of direct drive
HTS generators for wind power■ 2006 – present
■ Large scale projects involving the design and manufacture of HTS machines for renewable energy and marine propulsion.
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Direct Drive HTS Wind Generator
Project Part Funded by TSB
■ Design of 8 – 10 MW, 11 - 12 rpm HTS generator■ Design uses 2G (YBCO coated conductor) HTS wire■ Airgap design – torque acts on HTS wire (6 – 8 MNm to be transferred
from cold to warm parts) and stator copper rather than iron cores■ Design, manufacture and test of a scaled prototype – 500 kW at
30 rpm■ Uses 1G (BiSCCO) due to availability (42 km of wire) at time of wire
purchase■ Similar construction to full size machine
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HTS Model Wind Turbine Generator
The 8 MW, 12 rpm GeneratorThe 8 MW, 12 rpm Generator
5 m diameter, 2 m long, 100 tonnes5 m diameter, 2 m long, 100 tonnes
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OPT Powerbuoy – HTS Linear Wave Generator
Rating: 150kW average, 1 MW peakDesign / Feasibility Study 2008-2009
Five full size torque links manufactured for mechanical testing - (approx. 600mm long x 100mm diameter at ends)
Stator
Cold Field System
Bearing Assembly
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POSE2IDON
EU FP7 Funded Project, 4 years, €20m, 41 partners
■ Electric Ship Propulsion System■ HTS Generators incorporating power electronic providing DC output■ DC Distribution system■ HTS DC cable (Nexans)■ Zonal power supply units – DC to local AC■ HTS DC propulsion motors with integral power electronics■ Energy store to supply propulsion power for short periods■ Shore connection
■ Benefits■ Increased efficiency■ Zero emissions in and out of port■ More power dense motors and generators allowing electric propulsion
to be viable in smaller vessels■ Project includes design and build of demonstrator system
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POSE2IDON Demonstrator HTS Generator + HTS Motor
Demonstrators designed and manufactured using 2G HTS wire
■ Demonstrator generators (2):■ 1.5 MW at 1500 rpm■ Cold iron in rotor■ Stator with laminated iron teeth and solid copper coils■ Optimum for smaller machines
■ Demonstrator motor (1)■ 2 MW at 200 rpm■ Airgap HTS rotor winding■ Airgap stator winding uing
litz wire■ Optimum for larger HTS
machines
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HYDROGENIE – HTS Hydroelectric Generator
EU FP6 Funded
■ 1.7 MW, 214 rpm hydro generator■ Design, manufacture, test and put into commercial service■ Conventional stator■ Rotor with HTS field winding and warm, iron poles■ 50 Hz machine directly connected to grid
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HYDROGENIE – HTS Hydroelectric Generator
Rating: 1789kVA, 1700 kW, 5250V, 28 poles, 0.95 pf, 214 rpm
Conventional stator (warm)Conventional stator (warm)
Eddy current shield (warm)Eddy current shield (warm)
Turbine couplingTurbine coupling(warm)(warm)
Exciter (warm)Exciter (warm)
Vacuum chamber (warm)Vacuum chamber (warm)
HTS Field Coils (cold)HTS Field Coils (cold)
Rotor (warm)Rotor (warm)
Rotating couplingRotating coupling(warm/cold)(warm/cold)
Torque linksTorque links(warm/cold)(warm/cold)
Horizontal shaft machine driven by a Francis double turbine withHorizontal shaft machine driven by a Francis double turbine with integral thrust bearing.integral thrust bearing.Back of core diameter = 3m, Axial length = 1mBack of core diameter = 3m, Axial length = 1m
Conventional stator (warm)Conventional stator (warm)
Eddy current shield (warm)Eddy current shield (warm)
Turbine couplingTurbine coupling(warm)(warm)
Exciter (warm)Exciter (warm)
Vacuum chamber (warm)Vacuum chamber (warm)
HTS Field Coils (cold)HTS Field Coils (cold)
Rotor (warm)Rotor (warm)
Rotating couplingRotating coupling(warm/cold)(warm/cold)
Torque linksTorque links(warm/cold)(warm/cold)
Horizontal shaft machine driven by a Francis double turbine withHorizontal shaft machine driven by a Francis double turbine with integral thrust bearing.integral thrust bearing.Back of core diameter = 3m, Axial length = 1mBack of core diameter = 3m, Axial length = 1m
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Test results – June 2010Test results – June 2010
HYDROGENIEHigh Temperature Superconducting (HTS) Hydroelectric Generator
Rotor Cool Down Curves (Coil Nos. 1 to 28)
405060708090
100110120130140150160170180190200210220230240250260270280290300
Time
Tem
pera
ture
(K)
48 Kelvin (-225oC)Lowest coil temperature achieved
with just one cryocooler
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Test results – June Test results – June
20102010
HYDROGENIEHigh Temperature Superconducting (HTS) Hydroelectric Generator
Rotor Resistance during Cool Down (Coil Nos. 1 to 28)
0
1
2
3
4
5
6
7
8
9
10
Time
Res
ista
nce
(ohm
s)
115 Kelvin (-158oC)HTS coil resistances start to drop
95 Kelvin (-178oC)All 28 HTS coils are superconducting
(Zero resistance!)
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IET Innovation Award: Power / Energy 2009
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Cryocoolers + coolantCryocoolers + coolant
High temperature superconductors can be cooled by liquid nitrogen (77K)
Practical electrical machines still require high temperature superconductors
to be cooled to much lower than liquid nitrogen temperature (say 25 to 40K)
– e.g. using cold helium gas
Commercially available cryo-coolers can be used for 25 - 40 K operation providing >100W cooling power
Lower temperatures mean higher cooling costs but less HTS wire
Cooling and coolant transferCooling and coolant transfer
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Rotating couplingRotating coupling Usually takes the form of two concentric thin-walled tubes, one rotating inside the other. Seals used can be either PTFE or ferrofluid or a combination. Alignment, robustness and reliability are important.
Cooling and coolant transferCooling and coolant transfer
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High thermal conductivity materialsHigh thermal conductivity materials Choice of grades of copper with specific heat treatments and surface coatings to
enhance bonding and heat transfer. Allowance must be made for thermal differential contractions
between soldered or bolted materials.
Cooling and coolant transferCooling and coolant transfer
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Minimisation of heat loadsMinimisation of heat loads
Cryogenic Heat Load in a large HTS machine
Full Load Heat Budget
Internal Coil Heat Load, 6%
Conduction Heat Load, 46%
Radiation Heat Load, 48%
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Maintenance of Vacuum LevelMaintenance of Vacuum Level Pumps Component cleanliness – remove oxidation, rust, grease, oils etc. Trapped volumes – e.g. at the bottom of ‘blind’ bolt holes, laminations Getters
Getter elementGetter element
Minimisation of heat loadsMinimisation of heat loads
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Vapour Pressure of Common Gases
1.0E-11
1.0E-10
1.0E-09
1.0E-08
1.0E-07
1.0E-06
1.0E-05
1.0E-04
1.0E-03
1.0E-02
1.0E-01
1.0E+00
1.0E+01
1.0E+02
1.0E+03
1 10 100 1000
T, Temperature (K)
Pv, V
apou
r Pre
ssur
e (m
bar)
H2
D2
CH4
H2O
Ne
N2
CO
O2
Ar
CO2
Kr
Xe
TCTBAPv 1010 log.log +−= Using the Clausius-Clapeyron equation:
N2 at 30K and1 x 10-5 mbar
Feb 2008 21
Maintaining Vacuum LevelMaintaining Vacuum Level Cryopumping
Minimisation of heat loadsMinimisation of heat loads
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Low thermal conductivity materials – glass fibre, carbon fibreLow thermal conductivity materials – glass fibre, carbon fibre For wind generator – Transmit 8 MNm of torque with just over 20 W of For wind generator – Transmit 8 MNm of torque with just over 20 W of
conduction heat loadconduction heat load
GRP thermal support linkGRP thermal support link Superinsulated GRP linkSuperinsulated GRP link
Minimisation of heat loadsMinimisation of heat loads
Carbon Fibre thermal torque linkCarbon Fibre thermal torque link
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Multi-layer insulation (i.e. superinsulation)Multi-layer insulation (i.e. superinsulation) Aluminised Mylar and polyester Must provide sufficient overlap Must not over-compress Must not thermally short layers
Minimisation of heat loadsMinimisation of heat loads
Profile and thermally dump Profile and thermally dump current leads and wiringcurrent leads and wiring Use long lengths of conductor with profiled cross-sectional areas. Thermally dump to intercept conduction heat paths
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Infrastructure RequirementsInfrastructure Requirements
Testing Facilities / Information DatabasesTesting Facilities / Information Databases Converteam designed and built its own development test facilities Warwick University and Cambridge University provided crucial support Daresbury, The Rutherford Appleton Laboratory and Suppliers helped with their expertise
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Key enablers for HTS machines
Cost Reduction
■ Reduce the cost of HTS wire■ All chemical coated conductor manufacturing process■ Volume Production – chicken and egg as it requires a mass market for
HTS machines■ Reduce the cost of cryogenic and vacuum manufacturing
■ Components such as cryostats and large stainless steel structures■ Investigate use of lower cost materials not normally used in cryogenic
and vacuum enginnering
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Key enablers for HTS machines
Industrialisation of cryocoolers Low maintenance or preferably maintenance-free Low susceptibility to vibration etc. Able to withstand high 'g' forces due to rotation – for rotor mounted coolers Higher efficiencies
Industrialisation of helium transfer rotating coupling Robustness is very important Long term reliability is required Reduced susceptibility to misalignment
Industrialisation of instrumentation and components e.g. high vacuum pressure gauges, valves, etc. capable of withstanding high 'g' forces due to rotation.
Industrialisation of high vacuum pumps i.e. capable of withstanding high 'g' forces due to rotation Low maintenance / maintenance-free
Supplier chain and test facilities Ideally local to project design and build Should use universities more
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Thank you for your attention
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