Interfacing a Hydrogen Fuel Cell and Flywheel to the Analog Model Power System

March 11, 2005

Group 1 (Fuel Cell)

Adam Lint adam.lint@uidaho.edu

Chris Cockrell cock1258@uidaho.edu

Daniel Hubbard hubb3332@uidaho.edu

Group 2 (Flywheel)

Gavin Abo abo6715@uidaho.edu

Nate Stout stou6862@uidaho.edu

Nathan Thomas thom5938@uidaho.edu

TABLE OF CONTENTS 1 Summary .............................................................................................................................1

1.1 Objectives ............................................................................................................1 1.2 Significance of the project ...................................................................................1 1.3 Methods................................................................................................................1

2 Project Description..............................................................................................................2 2.1 Objectives ............................................................................................................2 2.2 Significance of Project.........................................................................................2 2.3 General Work Plan...............................................................................................3 2.4 Methods and Procedures ......................................................................................3

2.4.1 Fuel Cell and Flywheel .........................................................................3 2.4.2 Inverting the DC Signal ........................................................................4 2.4.3 Interfacing .............................................................................................4

2.5 Additional Considerations ...................................................................................4 2.6 Technical Advisor................................................................................................4

3 Bibliography .......................................................................................................................5 4 Credentials ..........................................................................................................................5 5 Schedule..............................................................................................................................6 6 Budget .................................................................................................................................6 7 Safety ..................................................................................................................................6 APPENDIX A: Credentials....................................................................................................A1

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1 Summary 1.1 Objectives

One primary objective for this project is to interface an Avista SR-12 hydrogen fuel cell

with the University of Idaho ECE department’s Analog Model Power System (AMPS). Team

HydroFly will create a three-phase AC voltage from the DC output of the fuel cell in order to

accomplish this goal.

The second primary objective is to implement a simulated design of a flywheel energy

storage system and interface that system to the AMPS. This system will detect and correct

voltage sags by temporarily providing power to the AMPS when needed.

1.2 Significance of the Project

The AMPS currently provides students with the opportunity to explore and understand a

typical power transmission system. The ECE department wishes to expand and improve this

system to include alternative energy sources and voltage sag correction. This will further

facilitate the learning experience for students and enable them to experiment with new

technologies in the power industry.

1.3 Methods

In order to accomplish the first objective, a DC to DC converter must be designed to

regulate the fuel cell’s DC voltage to an acceptable level. This DC voltage must then be inverted

to a 208V three-phase 60Hz signal and connected to the AMPS.

For the flywheel, Team HydroFly will implement a simulated design by Satish Samineni

[1]. This implementation will output a DC voltage from the flywheel motor and invert this

voltage to a 208V three-phase 60Hz signal.

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2. Project Description

2.1 Objectives

Team HydroFly will regulate the unsteady output of the fuel cell to 12V DC and invert it

to 208V three-phase AC. The fuel cell will be interfaced to the AMPS using this 60HZ AC

output and will provide power to the system for use as an alternative source of energy. Power

will only be allowed to flow in one direction and will be limited to 500 Watts peak because of

the limitations of the fuel cell [2].

The flywheel energy storage system simulations will be implemented on the existing

flywheel system with a DC drive to rotate the flywheel. Secondly, the DC voltage generated by

the flywheel motor will be inverted to 208V 3-phase AC in the same way the fuel cell’s output

was inverted. The flywheel system will only be engaged when a voltage sag is simulated and

detected on the AMPS. The flywheel will be able to handle up to a 100% voltage sag by

boosting the voltage up to a level within a 5% tolerance of the normal operating voltage.

2.2 Significance of the Project

In the mid 1990’s, the University of Idaho acquired the Analog Model Power System

(AMPS) from Idaho Power [3]. The AMPS is located in the basement of the Buchanan

Engineering Laboratory on the university’s campus in Moscow, Idaho. The purpose of the

AMPS is to provide insight into the workings of a power transmission and distribution system.

The main source of power is from the utility (Avista), and currently a generator is interfaced with

the AMPS to provide additional power to the system when needed.

In addition to the generator, the UI has obtained an Avista SR-12 500W fuel cell from

Genesis Fueltech [2]. This fuel cell represents one of many alternative energy sources available

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in the 21st century; therefore, modeling this energy source on the AMPS would be a valuable

learning tool for ECE students.

A flywheel will be used to correct voltage sags that can occur in AMPS. This models an

alternative energy storage system useful for keeping the voltage on the system within given

tolerances. This sag correction protects equipment that must operate within a very narrow

voltage range.

2.3 General Work Plan

For the fuel cell, Team HydroFly will first regulate the output of the fuel cell. This

regulated output will then be converted to an acceptable DC voltage level. The DC voltage will

be inverted to a 208V three-phase 60Hz signal to interface with AMPS.

The flywheel design will be implemented using the simulation data. This design outputs

a DC voltage that will need to be inverted to a 208V three-phase 60Hz signal in order to interface

the design with the current system.

2.4 Methods and Procedures

2.4.1 Fuel Cell and Flywheel

The DC voltage from the fuel cell varies from 23V to 43V [2]. For this reason, it needs

to be regulated to a steady 12V. This will be accomplished by using a DC to DC Buck

converter. Alternatively, a Buck-Boost converter could replace the Buck converter making it

possible to obtain a 24V output. Either converter will need to accept a wide range of input

voltages and output a steady signal with no more than ± 1V error. These converters should be

able to handle 500 Watts peak power.

Satish Samineni’s simulation involves rotating the flywheel with a DC drive. When a

voltage sag is detected (up to 37%), the current through the flywheel motor is reversed thereby

supplying power to the AMPS to correct the sag.

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2.4.2 Inverting the DC signal

The regulated DC signals from both the fuel cell and the flywheel motor need to be

transformed to a 208V 3-phase AC signal. This will be accomplished by purchasing a 3-phase

sine wave AC inverter. Series transformers will be utilized to step the voltage up and

synchronize the systems with the AMPS. An alternative method would be to drive a one

horsepower induction machine to generate a three-phase AC output. Either design should be

rated to 500W peak power input.

2.4.3 Interfacing

The fuel cell interface design will require that the working prototype for the DC to DC

converter and DC to AC inverter be mounted on a panel to be interfaced to the inverter in a neat

and organized fashion. This panel will then be used to fully interface the fuel cell to the

AMPS—utilitzing the chosen voltage inversion method.

The flywheel design will require that the simulated design be constructed in a way that

makes it simple to connect with the AMPS. However, the flywheel should only provide voltage

to the AMPS when there is a voltage sag and should charge to full capacity when not in use.

This system should be presented in an organized fashion similar to the fuel cell design.

2.5 Additional Considerations

In the future, fuel cells could be used as environmentally safe energy sources because the

inputs are hydrogen and oxygen, and the only significant outputs are water, heat, and electricity.

The flywheel is also an environmentally safe energy storage system. In addition, most

components of the fuel cell and the flywheel can be recycled.

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2.6 Technical Advisor

The technical advisors for this project are Dr. Herb Hess and Dr. Brian Johnson from the

Department of Electrical and Computer Engineering at the University of Idaho in Moscow, ID.

They will be providing support, when needed, in terms of opinions and thoughts on the designs

for our project. They will also provide assistance with facilities and the transportation of

equipment for our project. Their extensive experience with power engineering will be a great

asset for our team. Members of our group will meet with Dr. Hess and Dr. Johnson each week to

discuss our progress. At least once a month, our entire team will meet with Dr. Hess and Dr.

Johnson for a more detailed progress report and discussion of our future plans for the project.

They both will be receiving copies via email of important correspondence and paperwork with

respect to our project.

3. Bibliography

[1] S. Samineni, B. Johnson, H. Hess, and J. Law, “Modeling and Analysis of a Flywheel

Energy Storage System with a Power Converter Interface,” presented at the International

Conference on Power Systems Transients (IPST), New Orleans, USA, 2003.

National Aeronautics and Space Administration John H. Glenn Research Center at Lewis

Field.

[2] N. Fletcher. (2002, Mar). Avista SR-12 PEM Hydrogen Fuel Cell. University of Idaho.

Moscow, ID. [Online]. Available:

http://www.ece.uidaho.edu/hydrofly/documents/FuelCell.pdf.

[3] AMPS User Guide. University of Idaho. Moscow, ID. [Online]. Available:

http://www.ece.uidaho.edu/hydrofly/documents/AMPS_User_Guide.pdf

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[4] Starting Procedure of TNA (Transient Network Analyzer). ECE 525. University of Idaho.

Moscow, ID. [Online]. Available:

http://www.ece.uidaho.edu/hydrofly/documents/TNAoperate.pdf.

4. Credentials

See Appendix A.

5. Time Schedule

Figure 1.

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/2005

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Initial Design for Prototypes

Project Briefings (weekly - Semester 1)

Ordering Voltage Inverters and Buck Converter

Design Review

Interface Components to Fuel Cell

Implement simulation for Flywheel System

Demonstrate Working Prototype

Project Report and Notebook Due (Semester 1)

Summer Break

Project Briefings (weekly - Semester 2)

Interface Fuel Cell Components to AMPS

Interface Components to Flywheel

Revise Voltage Control System

Interface Flywheel to AMPS

Finalize Protection Circuitry

Complete/Debug Interfacing to AMPS

Final Product Demonstration/Release/Final Report

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6. Budget

Item Estimated Costs Printed Circuit Boards $200 DC/DC Converter (1) $50 DC/AC Converters (2) $2000 Transformers (2) $100 Microcontroller $250 Compiler $250 Labor costs (1000 man hours) $25,000 Other:

Project Display Costs $75 Hydrogen $45 Design Poster/Report Binding $30

Total $28,000

7. Safety

The AMPS system operates on a high voltage AC signal that can cause serious injury or

fatality and should only be operated with two or more people in the lab. High voltage capacitors

may be unenclosed and could be charged. People in the lab should be careful not to touch the

capacitor leads. Protective circuitry will isolate the flywheel and fuel cell from the AMPS.

Since the fuel cell uses compressed hydrogen gas, open flames should not be present in the

laboratory, and the main hydrogen valve should be turned off before leaving the lab.

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Appendix A: Credentials

Gavin Abo

MSC 1778 1080 W 6th St Moscow, ID 83843 (208) 885-9577 Email: abo6715@uidaho.edu

Education Student, Senior Level Standing Bachelor of Science: Electrical Engineering University of Idaho Expected Graduation Date: December 2005 GPA: 3.49/4.0

Relevant Coursework Energy Systems I Digital Logic Programming Design + Algorithms Electromagnetic Theory Microcontrollers Senior Design I Signals and Systems I Digital Logic Electronics I Electrical Circuits I + II

Chris Cockrell

430 Taylor Ave. Apt #2 Moscow, ID 83843 (208) 882-4769 Email: cock1258@uidaho.edu

Education Student, Senior Level Standing Bachelor of Science: Electrical Engineering University of Idaho Expected Graduation Date: December 2005 GPA: 3.00/4.0

Relevant Coursework Energy Systems I + II Digital Logic Power Electronics I Electromagnetic Theory Microcontrollers Senior Design I Signals and Systems I + II Digital Logic Electronics I Electrical Circuits I + II Intro to VLSI Design Information + Code Theory Mathematical Methods for Physicists Discrete Math

A2

Daniel Hubbard

600 University Ave Moscow, ID 83843 (208) 885-2966 Email: hubb3332@uidaho.edu

Education Student, Senior Level Standing Bachelor of Science: Electrical Engineering University of Idaho Expected Graduation Date: December 2005 GPA: 3.80/4.0

Work Experience INTERNSHIP – MODULE PRODUCT ENGINEER Micron Technology, Inc.

• Collaborated with design engineers to improve capabilities of memory test equipment

• Worked to test/troubleshoot latest DRAM Memory Modules for computers • Contributed in a team research project for a capacitor reduction study

Relevant Coursework

Energy Systems I Digital Logic Digital System Engineering Electromagnetic Theory Microcontrollers Senior Design I Signals and Systems I Digital Logic Electronics I + II Electrical Circuits I + II Intro to VLSI Design

Adam Lint

215 Henley Apt. #302 Moscow, ID 83843 (208) 412-8997 Email: adam.lint@uidaho.edu

Education Student, Senior Level Standing Bachelor of Science: Electrical Engineering University of Idaho Expected Graduation Date: December 2005 GPA: 3.55/4.0

A3

Work Experience TECHNICAL SUPPORT REPRESENTATIVE University of Idaho

• Involves close communication with many customers • Requires strong problem solving and organizational skills • Emphasizes teamwork and group problem solving skills

Relevant Coursework

Circuits I + II Electronics I + II Digital Logic Microcontrollers Energy Systems I + II Signals and Systems I + II Electromagnetic Theory Power Electronics

Nate Stout

860 N. Garfield St Moscow, ID 83843 (208) 882-4769 Email: stou6862@uidaho.edu

Education Student, Senior Level Standing Bachelor of Science: Electrical Engineering University of Idaho Expected Graduation Date: December 2005 GPA: 3.18/4.0

Work Experience INTERSHIP – MAINTENANCE ELECTRICAL ENGINEER Grand Coulee Dam

• Involved troubleshooting and verification of power systems

Relevant Coursework Circuits I + II Electronics I + II Digital Logic Microcontrollers Energy Systems I + II Signals and Systems I + II Electromagnetic Theory Power Electronics

A4

Nathan Thomas

207 West 10th Apt. #7 Moscow, ID 83843 (208) 882-7344 Email: thom5938@uidaho.edu

Education Student, Senior Level Standing Bachelor of Science: Electrical Engineering University of Idaho Expected Graduation Date: December 2005 GPA: 2.8/4.0

Work Experience TELE-DATA INSTALLATION System Tech

• Involved installation and troubleshooting of Fiber optic/CAT5/CAT6 cable

Relevant Coursework Circuits I + II Electronics I Digital Logic Microcontrollers Energy Systems I + II Signals and Systems I + II Electromagnetic Theory Power Electronics

A5