1| 10/17/2005BOEING is a trademark of Boeing Management Company.Copyright © 2004 Boeing. All rights reserved.
Phil Johnson FESS Program Manager and FES Principal Investigator Boeing Phantom Works
Energy Storage Systems EESAT October, 2005
Design, Fabrication, and Test of a 5 kWh Flywheel Energy Storage System Utilizing a High Temperature Superconducting Magnetic Bearing
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Superconducting Flywheel Development
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ACKNOWLEDGMENTS
• Funded in part by the Energy Storage Systems Program of the U.S.Department Of Energy (DOE/ESS) through Sandia National Laboratories (SNL).
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Superconducting Flywheel Development
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Flywheel Energy Storage Systems
Objective:•Design, build and deliver flywheel energy storage systems utilizing high temperature superconducting (HTS) bearings tailored for uninterruptible power systems and off-grid applications
Goal:•Successfully integrate FESS into multiple demonstration sites through cooperative agreements with DOE and contracts with Sandia National Labs
Deployment of a demo system, shown in relation to diesel genset and balance of system.
Status: •The 1 kWh / 3 kW test was successful•The design upgrade of the 5 kWh rotor is complete•The 5 kWh / 100 kW is currently in integration testing•The 10 kWh / 3 kW achieved many of the program design goals•The design upgrade of the 10 kWh rotor is complete•Preliminary designs started for 30 kWh / 100 kW system
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Flywheel Energy Storage Systems Basic Operation
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Flywheel Energy Storage System
• Why Pursue Flywheel Energy Storage?• Non-toxic and low maintenance• Potential for high power density (W/ kg) and high energy density
(W-Hr/ kg)• Fast charge / discharge times possible• Cycle life times of >25 years• Broad operating temperature range
• Why use high temperature superconducting bearings?• Very low bearing losses to extend the idle mode• HTS bearings will support ultra high-speed flywheels
– (Energy = (1/2) (Moment of Inertia) (Spin Speed)^2)
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Charge Retention Comparison of Flywheels and Battery
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Typical Load Profile for Remote Village in Alaska
• Now served by multiple diesel systems• Reasonable match for 50 kW FESS
• Data provided courtesy of Alaska Energy Authority
Kwigillingok, Alaska (population 338)Photo and data credits Virtual Tourist.com &
encyclopedia.thefreedictionary.com
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Proposed System Architecture for Deployment of a 5kWh / 50 kW Flywheel Energy Storage System
Benefits of using FESS instead of idling 2nd generator on standby• Reduce generator maintenance by 50% (estimate)• Reduce fuel costs by $80k/yr (estimate)• Lower pollution (air and noise)
50 kWWind
Turbine
50 kWWind
Turbine
100 kWDieselGenset
50 kWDieselGenset
50 kW / 5 kWhFlywheel
FlywheelPower
Electronics
IntegratedHybridPowerControlSystem
Off GridVillage
Flywheel Energy Storage System would supply powerduring short peak demand periods
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Energy Storage Program 5 kWh / 50 kW Flywheel Energy Storage System Project Roadmap
Phase IV: Field Test
• Rotor/bearing• Materials • Reliability
• Applications• Characteristics• Planning
• Site selection• Detail design• Build/buy• System test
• Install• Conduct field testing• Post-test evaluation
6/99 – 9/99
10/06 – 9/07
1/06 – 10/06
11/01 – 12/05
5/00 – 3/01 3/01 – 11/-01 (funding interruption)
1/04 – 05/-04 (funding interruption)Phase I: Application ID and Initial System Specification
Phase II: Component Development and Testing
Phase III: System Integration and Laboratory Testing
Phase I: Significant Outputs
•Unit characteristics
•System specification document
Phase II: Significant Outputs
•Prelim design complete
•HTS crystal array complete
•Material lifetime data
•Rotor upgrade complete
•Rotor qualification testing complete
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Flywheel Energy Storage System Key Components
Hex YBCO
100 kW or 50 kW Motor Generator
5 kWh Rotor
High temperature superconducting bearing
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Energy Storage Challenges in Early 2004 Resolved in 2005
Crack appearedafter clearcoat cure
•2004•Manufacturer’s process had not accounted for the stresses related to the elevated temperature of the cure cycle for the clearcoat•Data revealed a nearly 40% reduction in strength at the peak clearcoat cure temperature.
•2005•Problem is understood and corrected•Improved rotor design has resolved this issue•New rotor has completed fabrication•High-speed spin qualification testing complete
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High-Speed Quill Test of 5 kWh Rotor
5 kWh Rotor inside of the Boeing Quill Tester
Balance Features
5 kWh rotor total indicated runout(TIR) held to 0.002” during fabrication
As such, the rotor did not require any balancing prior to or during quill testing
Normal max operational speed is 22,500 RPMAnalysis complete and acceptable to 24,000 RPMQuill tested at 105% or 23,675 RPM
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Quill Test Dynamic Model vs. Quill Test Data
118
116
112
108
118
116
112
108
105104
100
96
9493
92
918884807672686460565248444036
33323028
2524201612
84
-4
0
4
8
12
16
20
24
28
32
36
-30 -20 -10 0 10 20 30
Shaft Radius, in
Axi
al L
ocat
ion,
in
Boeing-SANDIA-5kWh/50kW - .008" P-P Damper Motion
Model # 6100E (no orings behind upper ball bearing)
Rotordynamic Response Plot
00.0010.0020.0030.0040.0050.0060.0070.0080.0090.01
0.0110.0120.0130.0140.0150.0160.0170.0180.0190.02
0 5000 10000 15000 20000 25000Rotor Speed, rpm
Res
pons
e, In
ches
p-p
Major Amp
Boeing-5kWh - .008" P-P Damper MotionModel # 6100E (no orings behind upper ball bearing)
Sta. No. 118: Low er Rotor Response
xLrotor forced response plot showing the amplitude of unbalance vs rpm XLRotor Spreadsheet for Rotordynamic Analysis© Rotating Machinery Analysis, Inc.
Lower rim vibration vs speed 5kWh. 23,675 rpm (09/19/05)
0.0000.0010.0020.0030.0040.0050.0060.0070.0080.0090.0100.0110.0120.0130.0140.0150.0160.0170.0180.0190.020
0 5000 10000 15000 20000
Speed RPM
Vibr
atio
n, in
ches
p-p
unbalance
Lower Rim data from high-speed quill testing showing the amplitude of unbalance vs rpm
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Current DOE/Boeing Flywheel Cryogenics
LN2 & N2 (Two phase flow)
LN2
Cryostat (HTS)
Cold Head &LN2 Reservoir
Thermosyphon Operation
HTS Stability Bearing Cryostat Installed in DOE
Flywheel
HTS Bearing losses at 0.1% / hr including a cryogenic overhead factor of 20 at 77K
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Typical Cryogenic Data on HTS Bearing
22 April 05 Full Run Cryogenic Temperatures, 5 kWh / 100 kW FESS
5060708090
100110120130140150160170180190200210220230240250260270280290300
8:24 10:48 13:12 15:36 18:00 20:24
Time
Tem
pera
ture
(K)
#1 (in)#2#3 (out)#4InOutABSetpoint
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Direct Cooling Approach on HTS Bearing Moving Forward
HTS Stability Magnet Assembly (Boeing Patented)
G10 Scuff Plate
HTS Crystal Set (Boeing Patented)
Substrate
Heat Spreader
G10 Strong Back
G10 Support Structure
Cold Head ConnectionTo Heat Spreader
Benefits:Fewer parts, lower power requirementsEliminates the requirement for LN2Reduces maintenance
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Summary
• 1 kWh System• The 1 kWh / 3 kWh test was successful• Verified the HTS bearing approach and low losses
• 5 kWh Systems• The 5 kWh / 100 kWh is currently in full system integration testing with all
subsystems and components fully qualified• The high temperature superconducting bearing is performing very well• The design upgrade of the 5 kWh rotor is complete and validated by test• Direct cooling HTS approach for 5 kWh / 50 kW is moving forward into fabrication
and test
• 10 kWh System• The 10 kWh / 3 kWh achieved many of the program design validation goals• The design upgrade of the 10 kWh rotor is complete and moving into fabrication
• 30 kWh System• Preliminary design started for 30 kWh / 100 kW system
• Boeing is committed to continue Flywheel Energy Storage System efforts
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Acknowledgements
• I would like to acknowledge the help, timely advice, and program guidance of:
• Dr. Imre Gyuk and Paul Bakke of the U.S. Department of Energy through the Energy Storage Program and Offices of Energy Efficiency and Renewable Energy
• Nancy Clark and John Boyes of Sandia National Laboratories
• Boeing’s efforts in flywheels have been partially supported by the U.S.Department of Energy, Offices of Energy Efficiency and RenewableEnergy under the Cooperative Agreement DE-FC36-99G010825, Contract W-31-109-Eng-38, and Sandia National Laboratories Energy Storage Program Contract 24412.