Design, Fabrication, and Test of a 5 kWh Flywheel Energy Storage

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

Boeing Technology | Phantom Works

Copyright © 2004 Boeing. All rights reserved.

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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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.

Documents

Design, Fabrication, and Test of a 5 kWh Flywheel Energy Storage