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  • Periodic Reporting for period 2 - EcoSwing (EcoSwing - Energy Cost Optimization using Superconducting Wind Generators - World’s First Demonstration of a 3.6 MW Low-Cost Lightweight DD Superconducting Generator on a Wind Turbine)

EcoSwing Report Summary

Project ID: 656024

Periodic Reporting for period 2 - EcoSwing (EcoSwing - Energy Cost Optimization using Superconducting Wind Generators - World’s First Demonstration of a 3.6 MW Low-Cost Lightweight DD Superconducting Generator on a Wind Turbine)

Reporting period: 2016-03-01 to 2017-08-31

Summary of the context and overall objectives of the project

The EU-funded EcoSwing project aims at demonstrating world's first superconducting low-cost and lightweight wind turbine drivetrain—demonstrated on a large-scale wind turbine.

During the 4 year project the EcoSwing ambitions are high, the consortium aims at nothing less than the following objectives:

• Design, develop and manufacture a full scale 3.6 MW direct-drive superconducting (HTS) wind generator including a dedicated power converter suitable for current mass mainstream markets.
• Install this superconducting drive train on an existing modern wind turbine in Denmark.
• Operate the superconducting drive train for at least one year, giving the community confidence in superconducting wind generators.
• Prove that the new HTS drive train is cost competitive to state-of-the-art direct-drive permanent magnet generators of world class suppliers.
• Prove that the new HTS drive train can be cost competitive to state-of-the-art geared drive trains in series production.
• Develop and manufacture a cost-efficient cryogenics package that can be maintained atop a wind turbine by regular service people.
• Develop and manufacture a low-cost and maintenance-friendly HTS coil package based on second generation (2G) wire. This will contribute to maturing and stabilizing the European Superconductor industry.
• Address unique aspects of HTS drive trains (for instance in terms of hazard analysis) and provide a way for type certification.
• Develop a risk technical & financial management strategy in order to pave the way for market entry of HTS drive trains.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The Reporting Period 2 (RP 2) of EcoSwing ended on August 31, 2017. The EcoSwing generator assembly commenced on 06.06.2017 at JEUMONT. We can report here on a very eventful and extremely successful period:

• The project successfully reached Milestone M 3 – Design Complete
• EcoSwing fulfilled the 4 m directive by ENVISION with 3.6 MW direct drive generator, and provided the EcoSwing generator with the additional feature of ‘all-roads’ capability.
• THEVA continued manufacturing superconductor wire with performance exceeding EcoSwing requirements
• UTWENTE successfully took the test setup for the HTS coils into service.
• ECO 5 provided an initial risk assessment report assessing at EcoSwing from different angles.
• ECO 5 together with JEUMONT and UTWENTE procured parts. In extensive discussions with suppliers detailed CAD models and drawings have been made and exchanged. Manufacturing drawings were made by ECO 5 for rotor-related parts.
• DELTA built prototypes of industrial grade DAQ transducers. Along with a novel quench protection system, this was tested at UTWENTE’s type testing station.
• SHI Cryogenics selected a suitable cold head and developed a maintenance procedure.
• At SHI two types of rotary media coupling have been procured and co-engineered. Experimental validation of the rotary media couplings was completed successfully.
• JEUMONT completed the stator design. Most parts are in warehouse and manufacturing has commenced.
• IWES has finished integration planning into the testing infrastructure at its DyNaLab. This ground-based test is scheduled after first rotary tests at JEUMONT, and before the installation on ENVISION’s wind turbine.
• ENVISION has commenced detail integration planning into the turbine with required amendments to the turbine for this generator and its auxiliaries.
• DNV GL provides continually oversight and guidance on new technology introduction and pre-certification issues. Ultimately, this shall lead into a new drive train standard. Guidelines are under preparation with input from this project as well as others.

The consortium is progressing on its path towards installation of the EcoSwing generator on the existing modern 3.6 MW turbine in Thyborøn, Denmark.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Accomplishments of this reporting phase significantly strengthen the European industrial technology base:

• Major impact was on quality and stability of European HTS wire manufacturing capability. We are on a very good path to reaching the projected lifts of TRL and MRL.
• Additionally, a conventional workshop for coil winding was successfully introduced into to handling superconducting wire – lifting TRL and MRL for coil manufacturing to the projected levels.
• The consortium has identified near-to-commercial solutions for the cryocooling technology such as cryocoolers and helium couplings. Experimental qualification will commence shortly.
• The stator concept is pushed significantly beyond conventional state of the art technology by means of a conservative and robust approach.

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