1 | Program Name or Ancillary Text eere.energy.gov

Water Power Peer Review

PB500, 500kW Utility-Scale PowerBuoy Project

Dr. Philip R. HartOcean Power Technologies1590 Reed Road, Pennington, NJ 08534609-730-0400 x263 prh@oceanpowertech.comSept 27, 2011

PB150 (Scotland)

2 | Wind and Water Power Program eere.energy.gov

Purpose, Objectives, & Integration

This project focuses on the advancement of the OPT PB500 (500kW) PowerBuoy design, from TRL 4 to TRL 5/6.

– Design refinement requires extensive engineering and cost analysis, in a relatively short period of time.

– Hitting operational characteristics targets are challenging and requires careful analysis of all factors involved in producing, deploying, and maintaining a PowerBuoy of this scale.

– Power-Take-Off (PTO) Mechanism subassemblies require risk mitigation testing to ensure that the performance and reliability is as specified.

– PTO Mechanism assemblies require risk mitigation testing to ensure that the effect of combining technologies and subassemblies are carefully examined.

– Integration of PTO assemblies into the PTO system require risk mitigation to verify operational characteristic and ensure there are no interferences.

Solving the problems above allows for the realization of competitive energy pricing in the global marketplace.

The results of this project under DOE grant DE-EE0003645 will be used to conduct detailed design, fabrication, and assembly of PB500 PowerBuoy.

3 | Wind and Water Power Program eere.energy.gov

Technical Approach

The technical approach:– Stage-gated development program with clearly defined stage reviews.

– Clearly defined stage deliverables.

– Overseen by interdepartmental management and peers prior to proceeding to the next stage (go/no-go decision).

Key issues:– New technology adoption at the subassembly and assembly levels may introduce new

technical risks

– New Modular PTO approach could introduce packaging and arrangement issues

– Scale-up increases structure loading.

– Scale-up additionally places more emphasis on installation costs and maintenance considerations.

Unique approach:– Rigorous subassembly and assembly testing to mitigate subsystem and system technical

risks.

– Final PTO integration testing to ensure the implementation of new technology and arrangement does not introduce interference and alter PTO operational characteristics.

– Highly developed simulations/modeling validated by test.

– Extensive wave tank and ocean testing experience.

4 | Wind and Water Power Program eere.energy.gov

Plan, Schedule, & Budget

Schedule• Grant Initiation date: 9/1/2010• Planned completion date: 9/30/2012

FY 2011• Stage Gate 4 (Survival Condition Wave Tank Testing). 8/12/2011. (Complete)• Stage Gate 4 (Survival Condition Wave Tank Testing Data Analysis). 9/30/2011.

FY 2012• Operational Condition Wave Tank Testing. 12/19/2011.• PTO Preliminary Design (OPT SG5) Completion. 2/18/2012• PTO Detailed Design (OPT SG6) Completion. 4/27/2012• Structural and Mooring Concept Design (OPT SG4) Completion. 4/27/2012.• PTO Prototype Fabrication, Assembly, and Testing (OPT SG5) Completion. 7/31/2012• Structural and Mooring Preliminary Design (OPT SG5) Completion. 9/30/2012.• Go/no-go decision points will be made at the completion of each stage gate identified

above.

5 | Wind and Water Power Program eere.energy.gov

Plan, Schedule, & Budget

Budget: • There were no significant budget variances.• 6% or $145,593 out of the total grant amount of $2,400,000 has been

expended to date (August 31,2011)

Budget History/Plan

FY2010 FY2011 FY2012

DOE Cost-share DOE Cost-share DOE Cost-share

N/A N/A $ 166,267 $ 133,014 $ 2,233,735 $ 1,668,068

Fiscal Year FY11 Month Jul-11 Aug-11 Sep-11 DOE Budget Plan $ 24,642 $ 120,951 $ 20,674

DOE Budget Cum $ 24,642 $ 145,593 $ 166,267

Fiscal Year FY12

Month Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12

DOE Budget Plan $ 41,696 $33,842 $126,668 $ 68,657 $144,681 $149,936 $206,966 $ 247,015 $ 336,976 $ 307,394 $ 305,886 $ 264,018

DOE Budget Cum $ 41,696 $75,538 $202,206 $270,863 $415,544 $565,480 $772,446 $1,019,461 $1,356,437 $1,663,831 $1,969,717 $2,233,735

6 | Wind and Water Power Program eere.energy.gov

Accomplishments and Results

Technical Accomplishments:– Completion of survival condition wave tank testing, setting the

baseline design criteria that must be met (project milestone).– Float geometries set for acceptable modular PTO interface,

bounding the float design to allow the use of the MPTO.

Benchmark against technical targets:– Above accomplishments do not relate directly to technical

targets, however initial cost estimates on current rough design are approaching the specific lifecycle cost targets as defined in the project objectives.

7 | Wind and Water Power Program eere.energy.gov

Challenges to Date

Most important challenges:– Selection of optimal float geometry– Selection of optimal “mooring” method– Integration of subsystems and systems in PTO

Approach to issues or challenges faced:– Largest issue or challenge faced to date is driving the lifecycle

cost down while designing a robust, safe, and efficient PowerBuoy. Costs have been driven down through a careful design concept selection process, overseen by cross-departmental team members.

8 | Wind and Water Power Program eere.energy.gov

Next Steps

Project plans (PB500 Structural and Mooring Design (OPT SG4) under DOE grant DE-EE0003645):

Task Name % complete Start FinishWave Tank Testing – Survival Cond. 100 07/11/11 09/30/11Wave Tank Testing – Operational Cond. 20 08/22/11 01/13/11Tidal Compensation Concept Design 20 08/22/11 10/14/11Latching and Locking Concept Design 0 10/17/11 11/11/11Input Rod & Linear Seal Concept Design 0 10/24/11 11/18/11Central Cooling System Concept Design 0 11/07/11 12/09/11PTO Assembly Concept Design 0 11/07/11 12/09/11Structure and Mooring Concept Design 0 11/17/11 02/17/12Float Concept Design & Arrangement 0 02/20/12 03/16/12Ballasting System Concept Design 0 03/27/12 03/23/12PowerBuoy Deployment Concept Design 0 03/26/12 04/20/12Conduct Stage Gate 4 Review 0 04/23/12 04/27/12

9 | Wind and Water Power Program eere.energy.gov

Next Steps

Project plans (PB500 Power-Take-Off Preliminary and Detailed Design- OPT SG 5/6 under DOE grant DE-EE0003645):

Task Name % complete Start FinishAssembly of PTO subsystems 0 10/03/11 10/21/11Risk Mitigation testing of subsystems 0 10/24/11 11/18/11Assembly of PTO systems 0 11/21/11 12/23/11Risk Mitigation testing of PTO systems 0 01/02/11 01/27/12Conduct PTO Stage Gate 5 Review 0 01/30/12 01/31/12Assembly of PTO Mechanism 0 02/01/12 03/30/12Functional Testing of PTO Mechanism 0 04/02/12 05/11/12Cycle Testing of PTO Mechanism 0 05/14/12 07/13/12Generate PTO Test Report 0 07/16/12 07/27/12Conduct PTO Stage Gate 6 Review 0 07/30/12 07/31/12

– End of project for DOE grant DE-EE0003645 is scheduled for 8/31/2012.

10 | Wind and Water Power Program eere.energy.gov

Next Steps

Next steps:– Plans for expansion and continuation of all work produced in this

project would provide scope for a follow on DOE (or commercial) project.

• Construction of full-up PTO systems for PB500.

• Integration and assembly of PTO systems into PB500 unit.

• Construction of a full scale PB500 structure and mooring.

• Deployment/installation of the first PB500.

• Operation, Monitoring and Maintenance of first PB500.