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Ies keysan 03_03
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Ozan Keysan - IES SeminarMarch 2010
C-GEN Direct Drive System forMarine Renewables
March 2010
OZAN [email protected]
Institute for Energy Systems
The University of Edinburgh
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Overview
C-Gen Concept Project Description
Overview of Current Systems Direct Drive Design Options Design Method Optimization Method
Questions
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Direct-Drive Systems Advantages
Minimum moving parts High reliability Higher efficiency
Disadvantages Not off the shelf components Difficult to assemble Increased mass (Structural) Enercon 6MW
March 2010 Ozan Keysan – [email protected]– IES Seminar
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C-GEN Concept
Air-Cored PM No Attraction Force Easy Assembly Reduced Structure
Mass Modular Structure
Easy Assembly Custom Designs
March 2010 Ozan Keysan – [email protected]– IES Seminar
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C-GEN Prototypes
20 kW – 1st Prototype
15 kW – Myres Hills
Linear Prototype
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OYSTER
Oyster(1st version) Hydro-Electric Wave Energy Converter Launched November 2009 EMEC / Orkney 315kW
g
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OYSTER
Pros Simple/Robust No Offshore Electronics
Cons Reduced Efficiency Cost of High Pressure Pipe Installation
g
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Conceptual C-GEN Designs
Linear Partial Rotary Full Rotary
+ Easy to removefor maintenance
-End-stop problems-Exposed to sideway loading-Low active material utilization
+ Most efficient
-Heaviest type (structural mass)-Low active material utilization
+ No end-stop problems+Compact design+Max. material utilization
-Limited diameter-Reduced coil speed
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Direct Drive Case
Very low speed (~1rpm) High Torque Demand(~4MNm)
DD Generator 6m diameter, 120 tonnes Low Efficiency Material Cost > 10 years Electricity Income Economically Infeasible
g
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Single-Stage Gearbox
Direct Drive Maximum reliability High generator mass/cost
Single-Stage Gearbox More reliable than multi-stage Reduced generator size Higher utilization of magnetic material
g
Clipper Liberty 2.5MW
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Single-Stage GearboxSimulations with Different Gear
Ratios
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Optimum Design-OYSTER
Rating (4 x 300kW)
Diameter 4.1 m
Axial Length
0.9 m
Weight 14.6 t (2 x 7.3 t)0 10 20 30 40 50 60
70
75
80
85
90
95
100
Rotational Speed (RPM)
Eff
icie
nc
y(%
)
Efficiency vs. Rotational Speed
March 2010 Ozan Keysan – [email protected]– IES Seminar
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SRTT
SRTT (2x550 kW) – 18 rpm Tests on 1/5th scale
Low installation cost Can be towed to shore Survivability mode
g
SRTT 1/5th Scale
March 2010 Ozan Keysan – [email protected]– IES Seminar
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SRTT Stacking Options
X
RotorStructure
X
HubOuter Surface
FixedWindings
Radial Flux Axial Flux
Rotation Axis
Rotor
Stator Structure
Coils
Magnet
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Outer Stator Axial Flux
X
RotorStructure
X
HubOuter Surface
FixedWindings
•No stator structure•Lightest solution•Passive cooling with tidal current is possible•Minimum axial length•Identical machines (easy to control)
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Thermal Modelling
Increasing the thermal performance Utilizing tidal currents using cooling
ducts Water filled gap (Marinisation) Force cooling (fans, heat exchangers…)
March 2010 Ozan Keysan – [email protected]– IES Seminar
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How to Stack?
Independent Flux Paths No Mass Advantage Increased Power Rating
Usual Stacking
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How to Stack?Independent
Flux PathsCombined Flux Path
Reduced Inner CoreThickness
Reduced Axial Length Reduced core mass
(up to %50)Core thickness
is limited by magnetic saturation
Inner Core thickness is not limited by
magnetic saturation
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Grid Connection
DCLink
Control
Inverter Step-upTransformer
AC/DC
Control
G
G
AC/DC
Control
G
G
AC/DC
Control
G
G
Modular structure enables various options Grouped/Separate Operation Common/Separate Inverter AC or DC Transmission
GAC
DC
Single SRTT
GAC
DC
Single SRTT
GAC
DC
Single SRTT
..
.
ACDC
OFFSHORE ONSHORE
Step-upTransformer
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Designs with Varying Radius
With increased diameter Active Mat. Mass Structural Mass Axial length Input (Fluid)
Power
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Optimum Design
Number of Stacks
6
Rating 550 kW
Diameter 3 m
Axial Length 0.7 m
Average Efficiency
89 %
Weight 13 t
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Advantages of Direct Drive
Less buoyancy required
Increased efficiency Minimum moving parts Redundant generators Center of gravity
lowered Passive cooling
SRTT 1/5th Scale
March 2010 Ozan Keysan – [email protected]– IES Seminar
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AWS
AWS Linear PM Generator 2 MW – 2.2m/s Stator 5.6m Translator 8.4m
g
SRTT 1/5th Scale
1st Full Scale Prototype
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AWS Design OptionsSteel Core
Magnets
Coils
Runner
Steel CoreMagnets
Coils
Runner
TranslatorSupport
Pros Self-supporting core
structure Cons
Enclosed coils, decreased thermal performance
Weak translator support structure
Difficult disassembly
Pros Increased thermal
performance Strengthened
translator support Cons
Moment loading on translator
March 2010 Ozan Keysan – [email protected]– IES Seminar
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AWS Design Options
Pros Better utilization of translator
support Eliminated side moment
loading Strengthened translator
support Cons
Increased active material mass
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AWS Design Options
Number of Stacks
4
Rating (peak) 2 x 1MW
Translator Length
7.6 m
Stator Length 3 m
Average Efficiency
87 %
Total Weight 2 x 12 t
March 2010 Ozan Keysan – [email protected]– IES Seminar
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SeaGen
MCT - SeaGen 2x600kW – 14 rpm 16m diameter blades Pitch controlled Mono-pole structure
Maintenance Mode High installation cost
g
SeaGen – Maintenance Mode
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Speed – Torque Characteristics of MCT
Nominal Nominal Speed:Speed: 14.3 RPM14.3 RPMTorque: Torque: 450 kNm450 kNmPower: 675 kWPower: 675 kW
MaximumMaximumSpeed:Speed: 17.5 RPM17.5 RPMTorque: Torque: 650 kNm650 kNmPower: 1200 kWPower: 1200 kW
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Optimization Method
? 22 variables Design Constraints Variable Speed
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Structural Modelling
Deflection in C-Core Magnetic Attraction Force
Deflection in Rotor Structure Torque Gravity
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Integrated Design
Coupled Models Electromagnetic Thermal Structural
Reduced Design Time Realistic Model More chance to find
the real optimum solution
Electromagnetic Structural
Thermal
Machine DimensionsMaterial PropertiesAmbient Conditions
Magnetic Attraction Forces
Structure Dimensions
EfficiencyPower Output
Power RequirementCurrent Density
Air gap Deflection
Structure Temperature
Total MassMaterial CostPower Output
Efficiency
Design Constraints
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Optimization Method
Genetic Algorithm
Initial Population Size: 2500Population Size: 400Mutation ratio: 0.03• For each design candidate, cost function is
calculated and designs with least value survives for next generation.
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Optimization Method
Most Efficient Lightest Smallest CheapestGenerator designs are
PROBABLY NOT the OPTIMUM
Solution
Objective Function should include;
Manufacturing Cost Electricity Income Design Constraints For All Speed Range
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Optimization Method
10
1 int )()}(.(.{)()(i incomesconstrakimaterial xfxfwpxfxF
Material Cost-Steel-Copper-Magnet (very expensive)
Constraints Penalty-Power output-Electrical limitations-Magnetic limitations-Structural limitations-Thermal limitations
Income from electrical generation-Availability-Energy Price -Losses
COST FUNCTION
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Optimum Design
Number of Stacks
8
Rating 575 kW (Nominal)1200 kW (Max.)
Diameter 3.2 m
Axial Length 0.7 m
Average Efficiency
89 %
Weight 15 t
March 2010 Ozan Keysan – [email protected]– IES Seminar
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Summary
The C-Gen can be implemented to Marine Energy Converters More Reliable (Less Moving Parts) More Efficient Reduced mass compared to conventional DD systems
Integrated Model Approach + Genetic Algorithm Realistic Results Quick Not local minimums
Ozan Keysan - IES SeminarMarch 2010
Thank you for your attention