water power peer review
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1 | Program Name or Ancillary Text eere.energy.gov
Water Power Peer Review
Design of Submersible Generator for MHK Rob Cinq-Mars, President
Free Flow Energy, Inc.(800) 928-0435; Rob@FreeFlowEnergy.com6 September 2011
Project Number: DE-EE0004567
2 | Wind and Water Power Program eere.energy.gov
Purpose, Objectives
The design of a submersible generator – key features:– designed by motor/generator industry professionals– work with multiple turbine styles– critical subassembly of current energy conversion systems
Objectives:• accelerate MHK• improving performance• lowering cost, and • improve operation and maintenance
3 | Wind and Water Power Program eere.energy.gov
Project Team
4 | Wind and Water Power Program eere.energy.gov
Industrial Partners
5 | Wind and Water Power Program eere.energy.gov
Technical Approach - Tasks
1. Assess resources tidal and river for:– proper sizing– form factor– power rating– ambient operating conditions.
2. Determine appropriate topology
3. Electromagnetic circuit design
4. Mechanical design
5. Investigate Manufacturing Requirements
6. Cost Analysis
7. Commercialization and future research
6 | Wind and Water Power Program eere.energy.gov
Technical Approach – Key Issues
• MHK Generators - where wind generators were in ‘70s
• Eliminate gearbox (Rim Mount Design)
• Get topology, sizing, power and form factor right
• Components designed/manufactured by industry
• Work with multiple turbines
• Design for harsh marine environment
• Coupling method
7 | Wind and Water Power Program eere.energy.gov
Schedule & Budget
Schedule• Initiation date:11/1/2010• Planned completion date: 10/31/2011• Design Completed, report published, paperwork
complete
Budget: • On schedule, on budget, additional cost share provided
Budget History
FY2009 FY2010 - FY2011
DOE Cost-share DOE Cost-share
N/A N/A $160K $54K
8 | Wind and Water Power Program eere.energy.gov
Project - Preliminary
• Differences between renewable and conventional generation• Appreciate difference between power, energy and nameplate capacity• Differences between tidal and inland stream flows• Design for common siting conditions not extreme / rare• Lessons learned from wind• Many different turbine styles, sizes, & stages of development• Review and understanding of MHK state of art• Understanding of regulatory, permitting, siting• Acceptance of 35% efficiency• Baseline estimate of “realistic” siting conditions
9 | Wind and Water Power Program eere.energy.gov
Resource Assessment - Tidal
What’s Realistic?
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Resource Assessment - Area
Area & # Turbines to Generate 1 MW Assumes 35% eff (Gorlov)
11 | Wind and Water Power Program eere.energy.gov
Resource Assessment – Distribution & Area
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Resource Assessment - Tidal
UK Current Predictions
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Resource Assessment - Tidal
Tacoma Narrow Currents
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Resource Assessment - Tidal
Maine, Washington, and AK Velocity Frequency Histograms
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Resource Assessment - Tidal
Most recently – Georgia Tech / DOE Model, Mid Atlantic Currents
16 | Wind and Water Power Program eere.energy.gov
Resource Assessment - Tidal
Mid – Atlantic Depths
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Resource Assessment - Inland
18 | Wind and Water Power Program eere.energy.gov
Resource Assessment – Inland
chan_discharge Channel Flow The channel discharge in cubic feet per second
chan_width Channel Width The channel width in feet
chan_velocity Channel Velocity The mean velocity in feet per second
chan_area Channel Area The channel area in square feet
chan_depth (calculated) Channel Depth Average depth in meters
USGS Field Descriptions
19 | Wind and Water Power Program eere.energy.gov
Resource Assessment - Inland
Channel Velocity (mps)
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Channel Area - Inland
USGS Inland Data – Channel Area (m^2)
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Channel Depth - Inland
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Channel Discharge CMS
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Resource Assessment Cont.
Depth: 10 – 30 m (Top: Nav Clearance, Bottom: Permitted Sites)Salinity: 35 pptTemp: 35-90 F, 2-32 C
24 | Wind and Water Power Program eere.energy.gov
Analysis of turbines
Proprietary data was shared with FFE based upon completed NDAs. Data included CAD, test data, estimated torque / speed, TSR, etc.
This data was used to design a generator with a 2 meter diameter rated at 20 kW to connect to a 3m x 7m GHT, or an equivalent FloDesign turbine which presents a 5 m diameter to the flow. This is approximately 21 m^2 in cross section.
Comparable dynamic performance…
25 | Wind and Water Power Program eere.energy.gov
Selection of appropriate topology
Induction or Synchronous?(Field winding not reasonable)
AF, RF, or TF?Gearbox for speed?
(Rim mount)Iron core or coreless (magnet use and detent torque)Pole Count: more poles more voltage more power (balancing act)Cost and manufacturabilitySelection: RFPM Synchronous as wind is evolving to.
26 | Wind and Water Power Program eere.energy.gov
Gearbox Issue
Shaft seals are an issue, bow wakes, velocity fluctuations we selected rim mount speed enhancement with 2 m diameter
27 | Wind and Water Power Program eere.energy.gov
Generator Topology AF or RF
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What others do…
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What others do…
Air core?
Transverse Flux?
Weight reduction?
Increased magnet use
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What others do…
SmartMotor
Claims: concentrated windings, higher fill factor, higher efficiency
It appears from the description that this generator uses large gauge wire, hand inserted.
31 | Wind and Water Power Program eere.energy.gov
What others do…
VIEG – Variable Input Electrical Generator
This appears to be a “stacked generator.” They appear to be dynamically connecting windings in series at low speed and parallel at high. This appears to be quite costly, like purchasing multiple generators for one site.
32 | Wind and Water Power Program eere.energy.gov
Our generator
Radial flux, permanent magnet, synchronous, three phase, rim mount (2 meter diameter, 20 kW in 2 m/sec flow)
A conventional, buildable, cost effective approach capable of coupling to multiple turbine designs. The design leverages established and simple
manufacturing processes.
33 | Wind and Water Power Program eere.energy.gov
Concept with Single GHT
34 | Wind and Water Power Program eere.energy.gov
Concept with Double GHT
35 | Wind and Water Power Program eere.energy.gov
Concept with Ducted In-flow turbine
36 | Wind and Water Power Program eere.energy.gov
Electromagnetic Circuit Design
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Electromagnetic Circuit Design (cont)
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Mechanical Design – Segment Lam
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Mechanical Design – Segment Core
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Mechanical Design - Magnets
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Mechanical Design - Rotor
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Mechanical Design - Other
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Mechanical Design – Winding Diag.
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Other Work Completed
Cost Analysis
Manufacturability
Tooling and Fixturing Requirements
Protective Coatings
Refer to Final Report
45 | Wind and Water Power Program eere.energy.gov
Conclusion
Delivered what was proposed…
the design of a submersible generator capable of coupling to multiple turbine styles, designed by motor/generator design engineers specifically for MHK
Needed:
Turbines to move closer to production
Diversions to accelerate flow
A greater indication of commercial viability
46 | Wind and Water Power Program eere.energy.gov
Moving Forward – Latest News…
47 | Wind and Water Power Program eere.energy.gov
Moving forward: embracing diversions
http://www.youtube.com/watch?v=hEnANV8laRU
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