1	THE FUTURE GENSET FOR NAVY SHIPS IS NOW REALITY ALI FARAHANI FROM CALNETIX FREDERIC MATHA FROM Turbomeca Presented by Herman Artinian from Calnetix
2	Content TM1800 - ACL GTA: Project Objectives High Speed Alternator (HSA), Electronic Unit (EU), And Gas Turbine Configurations HSA Technical Risks and Mitigation Plans & Results HSA And EU Testing & Results Start Converter Full Speed @ No Load Full Current TM1800 vs. Diesel Genset Direct Drive Systems Benefits Status & Summary Questions?
3	ACL GTA: (Advanced Cycle Low-powered Gas Turbine Alternator) Project Objectives
4	ACL GTA Technology Part of the Royal Navy Vision Towards all Electric Ship
5	ACL GTA: Project Specific Objectives UPC to be within DG market price range Equivalent Specific Fuel Consumption (SFC) Reduced Life Cycle Cost (LCC) Benefits Reduced Weight & Footprint Environmentally compliant emissions Lower Noise & Vibrations Reduced maintenance requirement Reduced manning level
6	ACL GTA TM1800
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8	Decoupling Made Possible With: High Speed Alternator & Electronic Unit
9	HSA, EU, And Gas Turbine Configurations
10	HSA/EU Design Requirements: Operating Speeds and Power Ranges
11	Ambient Conditions & Operational Requirements
12	HSA Characteristics Machine Type PM Synchronous Operating Speed Range 19000 rpm – 22500rpm Over Speed 27000 rpm Maximum Output 2030 kW (HSA Output) Load Type Passive Rectification Minimum Output Voltage 800VDC (after rectification) Maximum Output Voltage 1800VDC (after rectification) Rated Current 1250 amps-rms
13	HSA Cooling Scheme Stator Cooling Medium: Water/glycol (60/40) Flow rate: 28 liters per minute Maximum inlet temperature 38^oC Estimated pressure drop 100KPa (excluding fittings) Rotor Cooling Medium: Air by integral cooling fan Flow rate: As a function of speed Ambient temperature -20^oC to 55^oC Ambient Pressure 96.5 kPa (assuming 500mm- H₂0 inlet pressure loss)
14	Electronic Unit Characteristics (sub-contracted to American Superconductor) Employs a conventional six pulse diode bridge to rectify the alternator voltage to provide an intermediate DC bus operating in the range of about 900-1500 volts during normal operation. Inverters based on conventional 1200 volt IGBTs programmed as DC to DC buck converters and stacked in series to accommodate the expected intermediate DC bus voltage range. A separate converter will provide the Alternator start function The Auxiliary power converter and battery control converters operate off an Auxiliary DC bus Water/Glycol cooling More than 98% efficient
15	TM 1800 Solutions: TI1800 Gas Turbine The most cost effective and simple design : Single shaft design operated at variable speed for fuel saving Only 2 anti friction bearings Single stage centrifugal compressor titanium Single can external combustor with Low Emission Technology No power gearbox, no accessory gearbox Only proven technology incorporated in its design PC-based Monitoring and Control System
16	TI1800 Gas Turbine (nick-name Mickey)
17	"2 Gas Turbines Built," 2 Gas Turbines Built, One More at Final Assembly 30 Hours Accumulated on Gas Turbine, Highly Instrumented
18	HSA Technical Risks and Mitigation Plans
19	HSA Major Technical Risks: Identified Early On In The Program Rotor Integrity Magnet Demagnetization Safety due to Internal Faults
20	HSA Technical Risk: Rotor Design Integrity Issues Manufacturing process scalability for large rotor with thick composite Rotor integrity and magnet retaining capability Rotor burst failure mode for containment analysis Mitigation Plan Build scale down rotors (1/3 magnet length with same cross-section) using same manufacturing process Spin testing
21	HSA Technical Risk: Scaled Down Rotor
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23	HSA Technical Risk: Magnet Demagnetization Issues Magnet demagnetization under high temperature and high electrical loading Mitigation Plan Short circuit testing of scale down unit to quantify demagnetization Demagnetization taken into account in HSA design based on previous experience Magnetized rotor is exposed to temp. above 180^oC during manufacturing process.
24	HSA Technical Risk: Short Circuit Testing
25	HSA Technical Risk: Internal Faults Issues/concerns Safety hazard including fire due to internal faults since permanents magnet excitation can not be turned off Mitigation Plan Transient thermal analysis for normal short circuit mode and failure mode Implementation of current sensors for over current and current unbalance detection
26	HSA Technical Risk: Internal Faults: Transient Thermal Analysis to Examine Short Circuit Condition Two different scenarios considered 3-phase balance short circuit across zero impedance Line-to-line short circuit across zero impedance Considered emergency shutdown sequence including coasting duration Assumed no water cooling available during this interval Air cooling from fan flow rate variation as a function of time Machine losses variation as a function of time Assumed worst case initial condition
27	Balanced 3-Phase Short Circuit: Max Component Temperature vs. Time
28	Line-to-Line Short Circuit: Max Component Temperature vs. Time
29	HSA And EU Testing & Results
30	Gas Turbine Start Converter Testing & Lessons Learned Speed Achieved by start converter: 14,500 RPM Verified the Start Capability While Spinning Down Higher than expected Back EMF was observed due to magnet strength being higher than those used in the models àHSA is electro-magnetically capable of producing more than 2MW HSA can be scaled down – length wise – to reduce the Back EMF and the windage loss and hence resulting in efficiency enhancements
31	Effects of Magnet Strength On Iron Loss: 26 MGO vs. 30 MGO
32	Full Speed – No Load Test Setup
33	Full Speed – No Load Test Setup - Schematic
34	Full Speed – No Load Model Estimates & Assumptions Only lump sum of losses could be measured via the torque-meter Models were used to estimate the factors contributing to the lump sum of losses Iron loss model was based on the stronger than expected magnets (30 MGO vs. 26 MGO) Windage loss estimates are based on 220F & 16.5psia air gap temperature and pressures, respectively Bearings losses were estimated based on 175F & 0.5gpm oil inlet temperature and total flow, respectively
35	Windage Loss For Different Air Gap Temperatures & Pressures
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38	HSA Loss Estimates: Full Speed – No Load (without the integrated fan) HSA Output Power ~ Zero Operating Speed 20,500 rpm Losses Model Measured Winding ~0 W N/A Iron 31,267 W Yes Rotor ~0 W Yes Stray ~0 W Yes Windage 14,342 W Yes Bearings 2,946 W Yes Fan Input Power ⁽¹⁾ ~0 W Yes Total 48,555 W 42,286 W Measured/Model = 87% Measured Input Torque: 19.66 N-m @ 20,540 rpm
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40	HSA Loss Estimates: Full Speed – No Load (with the fan) HSA Output Power ~ Zero Operating Speed 20,500 rpm Losses Model Measured Winding ~0 W N/A Iron 31,267 W Yes Rotor ~0 W Yes Stray ~0 W Yes Windage 14,342 W Yes Bearings 2,946 W Yes Fan Input Power ⁽¹⁾ 4,463 W Yes Total 53,018 W 47,613 W Measured/Model = 90% Measured Input Torque 22.18 N-m @ 20,500 rpm
41	HSA Full Current Test Setup - Schematic
42	HSA Full Current Performance Test Setup - Schematic
43	HSA Full Current Testing: Comments & Model Assumptions HSA #1 was loaded as a generator with AC resistive load banks Output wave forms were captured by: Yokogawa Power Meter PZ4000 Yokogawa DL750 Scope Input power was calculated from the torque and speed measurements Tested HSA #1 for 1,300 A - rated current is 1250 A Winding loss was estimated using the stator’s highest measured temperature of 150 C for analysis The Iron loss was estimated at 235 Hz for analysis The bearing, windage, rotor, stray, and fan losses were based on the same assumptions as those for full speed & no load
44	HSA Full Current Testing: 1300 A RMS
45	HSA Losses Model & Measured: Full Current @ Partial Speed HSA1 Output Power (measured) 788 KW (from Yokogawa Scope, 794 KVA @ 0.993 PF) HSA2 Input Power (measured): 798 KW (from Torque meter) Operating Speed (measured): 7,050 rpm (from Scope) HSA Output Current (measured): 1303 A rms (1250 A rms rated) Losses Model Measured Winding @ 150^oC 5,113 W Included Iron 7,328 W Included Rotor 300 W Included Stray 250 W Included Windage 947 W Included Bearings 423 W Included Fan Input Power 389 W Included Total 14,950 W 9,060 W Measured/Model = 60.6% Input Torque: 1082 N-m
46	TM1800 vs. Diesel Genset Provided by Turbomeca
47	TM1800 vs. Diesel: (Provided by Turbomeca) Installation & Physical Advantages
48	TM1800 vs. Diesel: (Provided by Turbomeca) Environmental Advantages
49	TM1800 vs. Diesel: (Provided by Turbomeca) Operational Advantages
50	TM1800 vs. Diesel: Maintenance Advantages
51	TM 1800: OTHER APPLICATIONS AS AN AUXILIARY POWER GENERATOR FOR HOTEL LOAD AND CRUISE PROPULSION, FOR FRIGATES, MINE COUNTER MEASURE VESSELS, LITORAL COMBAT SHIPS, FUTURE SURFACE COMBATANTS, ALL ELECTRICAL SHIPS, etc AS AN EMERGENCY GENERATOR FOR AICRAFT CARRIERS, etc
52	Direct Drive Systems Benefits
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54	Example Direct Drive Systems Size & Weight Advantages with an existing RR package (AG9140)
55	Direct Drive Systems: Other Applications
56	Status & Summary
57	HSA/EU: Program Status
58	Summary Feasibility of High Power, High Density, High Speed Alternators have successfully been demonstrated by Calnetix. Lower weight Small foot print High efficiency Manufacturability Decoupling the high speed prime mover from load using direct drive system offers benefits such as: Light weight and small size => release space for other usages High efficiency => fuel savings Reduced maintenance => reduced manning
59	QUESTIONS ?