Status of High Temperature Superconductor Cable and Fault Current Limiter Projects at American Superconductor

J. F. Maguire and J. Yuan

EPRI Superconductivity Conference Oak Ridge, TN November 12-13, 2008

Agenda

HTS Projects at AMSC HTS Project Objectives and Milestones Development Results of HTS Projects Conclusions

HTS Projects at AMSC

Cable Projects
- Transmission Voltage
LIPA 1 (BSCCO Wires) LIPA 2 (YBCO Wires)

- Distribution Voltage
Project Hydra Consolidated Edison

Fault Current Limiter Project

- Transmission Voltage
Southern California Edison

Projects Objectives
LIPA 1
Demonstrate a transmission voltage level HTS cable and outdoor terminations in an operational power transmission grid Demonstrate a 2G HTS transmission cable and a cable joint in an operational power transmission grid. Demonstrate an FCL cable technology and repairable cryostat. Demonstrate modular refrigeration system. Demonstrate HTS fault current limiting link between substations. Demonstrate feasibility of an underground installation of a fault current limiting HTS system in population condensed urban area Demonstrate standalone HTS fault current limiter based on 2G wires in an operational power transmission grid. Introduce HV into FCL

LIPA 2

Hydra Project FCL

Projects Specifications
LIPA 1
600m long using BSCCO wires
138kV/2400A, ~ 576 MVA Fault Current 51kA @ 12 line cycle (200ms) 600m long using YBCO wires 138kV/2400A, ~ 576 MVA Fault Current 51kA @ 12 line cycle (200ms)

LIPA 2

Hydra Project FCL

320m long using YBCO wires 13.8kV/4000A, ~ 96 MVA Fault Current 40kA @ 4 line cycle (67ms) 138kV/ 1200A Fault Current 63kA @ 4 line cycle (67ms) Fault Current reduction rate 36% (limit to 40kA)

Projects Timelines
Year LIPA 1
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

LIPA 2

HYDRA

FCL

Project Partners

OAK RIDGE NATIONAL LABORATORY

U. S. DEPARTMENT OF ENERGY

Development Results of HTS Projects LIPA 1

Transmission Voltage Cable Project Long Island Power Authority New York

LIPA 1 Project Team

Installation Site
Port Jefferson Shoreham

Wading River

Miller Place Terryville

Centereach

Superconductor

Holbrook Substation

10

Major Challenges of LIPA 1 Project

System Design
138 kV, 2,400 amp operation Survive 51 kA @ 200 ms fault Manage Through-Faults Manage larger cold contraction

HTS Conductor Design

- Handle real-world cabling stress using standard manufacturing equipment

Termination Design
- Qualify to 138 kV operation, 650 kV BIL - Safely manage voltage breakdown - Manage results from loss of cryostat vacuum
Worlds First Installation of a Transmission Voltage HTS Cable

11

LIPA 1 HTS Cable System

Power

SCADA

Heat

HV Termination

Cold Termination
Return Redundant Cooling & Control

Supply

12

Bulk LN2 Storage

LIPA 1 HTS Cable Design

Outer Cable Sheath LN2 Coolant HTS Tape Former

High Voltage Dielectric HTS-Shield Outer Cryostat Wall Copper Shield Stabilization Inner Cryostat Wall

13

Prototype Testing
A test program has been
defined together with the DOE review team based on existing standards

Tests included
- High voltage dielectric tests - High current tests - Hydraulic tests - Load cycles - Loss measurements

Type test performed prior starting manufacturing

14

Pre-Construction

15

Installation - Terminations
Terminations were
installed with the cable phase in place

No issues identified
during termination work

16

Installation - Terminations
Terminations were
installed with the cable phase in place

No issues identified
during termination work

17

Installation - Cable Pulling

Cable pulling operation was tested using a 70
meter long test setup to verify method and estimate force

Cable puling on site was achieved without

issues

Vacuum level of cryostat was checked before

and after pull

Pulling force was recorded and compared to

estimated values
Cable Pulling Force
20000 18000 16000 14000
Force [N]

10000 9000

. theoritical curve total (coef f 0,24) therotical (rolls) theoritical (cable in PE pipe)

Phase 1 Phase 2 Phase 3

8000 7000

12000 10000 8000 6000 4000 2000 0 0 100 200 300 400 500 600 700 Distance [m]

Force (N)

6000 5000 4000 3000 2000 1000 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 HTS cable distance in the PE pipe (m)

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Refrigeration substation

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Cable cool down

LIPA Cooldown Termination Temperature
PT 101 300 275 250 225 PT 601 model model

Predicted

Temperature (K)

200 175 150 125 100 75 50 0 48 96 Time (hours) 144 192 240

Actual

20

Cable Energization
AC-High Voltage test
completed successfully
- 1.5 Uo applied at each phase for one hour - PD measurement completed No partial discharge detected

24 hour dielectric soak test

completed successfully
- Cable connected to LIPA grid at one end

Cable connection at both ends

completed on April 22nd
- Operation with parallel overhead line for 24 hours - Operation without parallel path Cable Commissioning Successfully Completed afterwards

21

Cable Operation - Measurements

The cable system is monitored
regarding a variety of parameters to - Ensure safe operation - Gain measurement data to compare with design results Measurement data analyzed so far: - Cable cool down behavior - Cable cryostat thermal loss - Nitrogen pressure drop - Temperature increase due to dielectric loss - Temperature increase due to ACloss - Thermal behavior of termination (bushing) - Cable system time constants Cable System Measurements in very good Agreement with Design Results

22

Steady State Operation (I)

90 80 70
Phase Current (A) 400 350 300 250 200 150 100 Phase R Phase S Phase T

60 Total MVA 50 40 30 20 10 0 7/2/08 12:00 AM

50 0 7/2/08 12:00 AM 7/3/08 12:00 AM

7/2/08 12:00 PM

7/2/08 12:00 PM

7/3/08 12:00 AM

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Steady State Operation (II)

73

15.0 Inlet Pressure

700

72 Return Temperature 71
LN2 Pressure (bara)

14.5

600 LN2 Mass Flow Rate (g/s)

Temperature (K)

14.0 Flow Rate 13.5

500

70

400

69

13.0 Return Pressure

300

68 Inlet Temperature 67
12.5 200

66 7/2/08 12:00 AM

7/2/08 12:00 PM

7/3/08 12:00 AM

12.0 7/2/08 12:00 AM

7/2/08 12:00 PM

100 7/3/08 12:00 AM

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Sound Issues
Several questions regarding
noise at the site (during operation)

Conducted sound study

- 35 db at ambient - Source: refrigerator building - 50 db with refrigerator running

Acoustical Louvers
- Lowered sound signature during operation to 38 db (modeled)

25

Sound & Site Mitigation

26

Development Results of HTS Projects LIPA 2

Transmission Voltage Cable Project Long Island Power Authority New York

27

LIPA 2 Project Team

28

Major Challenges of LIPA II Project

System Design
- Integrate single phase fault current limiting phase into the existing system

2G HTS Conductor Design

- Address real-world cabling stress using standard manufacturing equipment

Cable Design
- Demonstrate field joint - Demonstrate field reparable cryostat

Develop a 20 KW modular high efficiency refrigerator

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LIPA II HTS Cable System

Existing HV Termination Existing Cold Termination

Power SCADA

Heat

Replacement 2G Phase

Field Joint
Return Redundant Cooling & Control

Supply

30

Bulk LN2 Storage

LIPA 2 HTS Cable Concept

Inner Cryostat Wall LN2 Coolant Cable conductor has to be redesigned for thermal contraction (and current limiting)

HTS-Shield Copper Shield High Voltage Dielectric Stabilization to be removed

Outer Cryostat Wall

31

LIPA 2 Wire
YBCO Coated Tapes
- Lower Tc, higher resistance substrate: Can be made to be current-limiting - Different dimensions and physical properties:

YBCO coated onto one side of buffered Ni-W substrate Brass laminated onto both sides
~ 0.3 mm thick, splices even thicker

Splices are being developed

32

Cable design and manufacturing process

Dummy cable approach to develop the
cable design
- Develop cable design based on modified modeling tools - Manufacturing of short samples

Measurement of electrical characteristics (AC-loss)

- Manufacturing trials using industrial machine adapted to HTS tape stranding - Testing of samples in terms of mechanical and high voltage aspects

Status
- Two different design options considered - First manufacturing trials (dummy cables) focus on one of the two designs

33

Dummy cable 01 - Current Status

Hollow flexible former
- Dummy cable is being produced now - Superior concept

Only small force due to thermal contraction Small cross-section, stainless steel:
High resistance, good for current limitation - Requires some effort due to flexibility of former in the machine - Preferred design

34

High Voltage Termination

LIPA 1 terminations design is kept for this project but adapted for the new YBCO HTS cable:
- Removal of the cable termination shrinkage management (blocking of the cable) - Adaptation of the cable connection for 2G wires

Status:
- Updating of the cable connection is in progress with different new brazing alloys studied - Continuation of the development required now some LIPA 2 cable samples in order to achieved some connection and mechanical tests and improved the components

35

High Voltage Termination

LIPA 1 terminations design is kept for this project but adapted for the new YBCO HTS cable:
- Removal of the cable termination shrinkage management (blocking of the cable) - Adaptation of the cable connection for 2G wires

Status:
- Updating of the cable connection is in progress with different new brazing alloys studied - Continuation of the development required now some LIPA 2 cable samples in order to achieved some connection and mechanical tests and improved the components

36

Superconducting Cable Joint

HTS cable joint
- Develop and test a straight joint to connect superconducting cables

Design of conductor connection Design of joint dielectric insulation Design of screen connection Design of joint cryostat

Cryostat for subscale test Cryostat for on site installation - Full prototype test of cable joint in the laboratory - Installation of a single cable joint on site

37

Status: High Voltage Joint

A first joint design has been set up considering two main physical constraints
- Thermal: no overheating in the central cable connection with nominal current (not in direct contact with liquid nitrogen)

- Electrical: E field management in an optimum dimension of the joint

Prototypes for testing assembly procedures successfully prepared and tested with nominal current in LN2 (temperature measurement)

38

Status: High Voltage Joint

The first design of the joint has been assembled in NEXANS Hanover testing laboratory in June/July 2008 First results on this component achieved in September 2008 AC withstand test 190 kV / 30 min Lightning impulse test 650 kV (+/-) Partial discharge measurement

39

Joint in the Test Field

Inlet Termination (Connection to the Transformer) Outlet Termination with the Joint inside

25 m Coated Conductor Cable

40

Field Repairable Cryostat

Field repairable cryostat
- Perform optimization study to determine cryostat vacuum barrier distance based on - Develop and demonstrate vacuum barrier manufacturing techniques - Develop improved thermal insulation system to perform under repair vacuum conditions - Demonstrate field repair in laboratory

Status of work
- Vacuum barrier manufacturing techniques

Various designs developed

- Improved thermal insulation system

Investigation of vacuuming behavior of alternative thermal insulation materials

41

Modular Refrigeration System Objective

Develop a new Refrigeration technology dedicated to long-length HTS cable with the main characteristics below

- Low operation cost

High efficiency Low maintenance

- Low refrigerator cost

Simple design Modular design

- High reliability - Long lifetime

42

Refrigeration System Objective

Develop a new Refrigeration technology dedicated to long-length HTS cable with the main characteristics below
Liquid nitrogen delivered LN2 pressure drop Cold power Efficiency Cooling Manufacturing cost target 72 K 3 bars 120 kW total - 20 kW Modules > 20% Carnot Air cooling (-20 / 50C) <$100/cold W series production

43

Refrigerator Development Status (Phase 1)

Progress made thus far
- Thermodynamic analyses of reverse Turbo-Brayton cycle - Cooler configuration scenarios - Numeric modeling of cooler configuration and Refrigeration sub components - Model validation - Creation of a numerical model for each cooler configuration - Optimization of each cooler configuration Completed Completed Completed Underway Completed Identified

44

Development Results of HTS Projects

Project Hydra
Distribution Voltage Cable Project Consolidated Edison New York City

45

Team Roles and Responsibilities

DHS S&T Division

AMSC Prime Contractor

AMSC System Design Wire Development Wire Manufacturing Project Management Technical Oversight System Hardware Development Altran Solutions Air Liquide Con Edison Utility Requirements Project Oversight Cable Manufacturing HTS FCL Cable System Site Cable and Accessory Installation Southwire Cable and Accessory Design

ORNL

50m Prototype Cable Test Site Technical Support

46

Installation Site

Worlds First FCL Distribution Cable to be Installed in Operating Grid

47

Program Structure
Currently Executing Planning
DHS/ HYDRA

Phase 1 System Development

Phase 2 System Installation

ORNL 50 Meter Test and Technical Support

Phase 1A Fault Current Limiting Cable technology

Phase 1B Stand-Alone Fault Current Limiting Technology

48

HYDRA HTS Cable System

Heat Power

Supply

Return

Refrigerator

HTS Cable

Return Line

49

Secure Super Grids Technology

Substation #1
138kV Transmission Bus

Substation #2
138kV Transmission Bus

Fast Switch (Circuit Breaker)

HTS Fault-Current Limiting Cable

Reactor

Conventional Copper Cable

13.8kV Distribution Bus

13.8kV Distribution Bus

Note: Red breakers are Closed Green breaker is Open

To Loads To Loads

50

Cable Design- TriaxTM by Southwire

HTS Layers Hollow Former Cryostat

Dielectric

Shield

51

3 m Cable FCL Tests

The prospective fault current of 60 kA was reduced to 44 kA on the
first cycle to < 30 kA at the end of the 140 ms duration fault

A perspective 140 ms fault current of 44 kA was reduced to 29 kA The voltage developed due to the heating was 8-11 V/m over the 140
ms duration fault

This was comparable to the design fault of 300-m cable which results
in ~ 10 V/m

Measured temperature increase to 85-95 K Re-cooling time to 77 K is 9 min No change in temperature measured after a 9.1kA, 270ms through
fault test

No change in temperature or voltage after a 2000 ms, 7.2kA overload

test (1.8X)
52

3m Cable FCL Tests

53

3 m Cable FCL Tests

54

Refrigerator Requirements
Refrigeration Cycle chosen is the Reverse-Brayton
- Best suited technology for high power applications (> 6 kW) - Best return on specific efficiency (We/Wc) vs. capital cost

Flexibility Requirement:
- 80% of time at 50% heat load on HTS cable

Reliability
- Redundancy accomplished at component level: compressors, pumps, expanders, electronics, instrumentation - No 1st order single point of failure allowed

Capacity Margin
- Current design has 50% safety margin to the expected losses

55

Reverse Brayton-Cycle Hardware

- Estimated foot print size & weight 13 m x 7 m ( 42 x 25 ) + roof for cooling water exchanger ~ 24 000 kg ( 53 000 lbs ) empty Fits within available space

56

Development Results of HTS Projects

FCL Project
Transmission Voltage FCL Project Southern California Edison California

57

Team Roles and Responsibilities

DOE SPE - SCE AMSC Prime Contractor
Nexans HV Termination

AMSC System Design Wire Development Wire Manufacturing Project Management Technical Oversight System Hardware Development

SCE Utility Requirements Project Oversight HTS FCL System Site

Siemens FCL Module and Accessory Design FCL Manufacturing FCL Module and Accessory Installation

HV Consulting

Air Liquide

58

SuperLimiterTM Demonstration Site

Selection criteria
- Voltage - Transmission planning - Civil engineering
Riverside

Valley Substation selected Located near Riverside, CA in a

desert climate

Valley Substation

Analysis used to select bus tie

application

Significant load growth planned

over the next 10 years
- Tapped external reactor enables device to easily adapt The Valley Substation is selected

59

SCE Profile
50,000 Mile2 Service Territory 120 years of service $17 Billion T&D Assets

Distribution
85,000 Circuit Miles 690,000 Transformers

Customers
4.7 Million Meters 13 Million Customers 22,889 MW Load

Transmission
12,600 Circuit Miles 4,200 Transformers

SCE is one of the largest utilities in the United States

60

SuperLimiterTM Southern California Edison

SCE is investing in the future
- > $3 billion invested in T&D over the last five years - $11 billion planned infrastructure investments over the next decade.

SCE has considerable experience with

superconducting Fault Current Limiters
- Since 1993 in DOE-SPI, tested a 15kV FCL in 1999 - SCE role in this program is Specifying requirements Providing the prototype operation site

138 kV Transmission Voltage level FCL addresses

- Elimination of CB and other equip. replacement
- Enhanced reliability, shorter customer outages - More stable, higher-quality electricity supply - A self-healing grid
July 1999: FCL at a Southern California Edison substation

SCE has unique experience with HTS FCL technology and this program extends this to transmission voltage levels

61

SuperLimiterTM Major Elements

Cryostat sized for modular expansion

Valley Substation 138kV termination in operation at LIPA site

Insulation Stainless Strip HTS Film NiW Strip Solder

Cooling System Similar to Navy Motor Program N+1 Redundancy

Bifilar 2.2 MVA medium voltage module tested Jan. 2007

1.2 cm insulated HTS tape based on standard insert

Design based on validated components is designed for modular expansion

62

FCL Operating Principle

Supply Bus During fault conditions, superconductor becomes resistive and with reactor, limits current

Normal State Resistance

Virtual Switch
Superconductor

Under normal conditions, power flows through superconductor with virtually no impedance and system is Physical Switch electrically invisible Shortly after fault clears, power resumes flow through superconductor

Reactor Physical switch opens to protect FCL system; reactor maintains current Load Bus

FCL system operation is based on simple operating principles

63

Basic Specifications
Requirement
Nominal Voltage Insulation Class Nominal Current Maximum Site Unlimited Fault Current Site Limited Current Trip Current

Prototype System
115kV rms 138kV 1,200A 63kA

Production Units
115-138kV 138kV
Opening Switch

Reactor
Sized to Limiting Requirements

Load

>2,000A >80kA

Source

Switch Control

FCL Vessel Assembly

40kA

As required by customer
Protection and DAQ System Refrigeration System
Power Heat

1.6pu

As required by customer

Team has approved a working specification for system

64

SuperLimiterTM Operating Conditions

Constraints
- No bubbles around the bottom of bushing sub-cooled LN2 - Termination dielectric requirement P > 3bar - Fast recovery time saturated LN2

Solution
- Operate FCL in sub-cooled LN2 with nominal operating temperature lower than design point.
FCL design at temperature 74K@5bar(a), but operate at temperature 72K@5bara Power Temperature margin determines the number of faults the system can absorb before system is off-line to re-cool 2K margin allows LN2 to absorb 57MJ energy (~6 faults) 5 bar pressure will allow LN2 in coil vicinity absorb fault energy without bubbling
FCL operates at high pressure sub-cooled LN2 temperature

FCL Vessel Assembly

Refrigeration System

Heat

65

SuperLimiterTM Refrigeration System

Heat Load
Cryostat Other Refrig. System
Level

Value (W)
850 200 900 350 1950

Terminations
Pressure

Lines, Valves, Bayonets AC Losses

Level

Total Max. Predicted Planned Capacity

4250 6000

AMSC has operated HTS systems in utility/harsh industrial conditions

- LIPA and TVA/SuperVAR Project

DOE-FCL system based on lessons learned in those systems

- Phase 1b open cycle option shown above - Phase 2 - replace with closed cycle modification

Simplified, COTS based system Significant margin planned for prototype system
Refrigeration based on experience at LIPA and other AMSC utility HTS systems

66

SuperLimiterTM Test Site

Present Installation: 4-3Phase, 336/448/560 MVA 525-120 kV, OA/FOA/FOA Transformers. Sectionalized 115 kV bus each section fed by 2 transformers Max. single-phase-to-ground fault = 30 kA All 115 kV CBs rated 40 kA Planned Future Installation: Load growth in the area and interconnection of new generators will require additional transformers Fault current duty will rise above 40 kA
C 115 kV AB 115 kV Serrano 500 kV A B 500 kV Devers 500 kV Inland Empire

115 KV Outgoing 1000 MW Feeder Future Gen (Studied)

Bus Tie (Selected)

115 kV

A bus tie application at the Valley Substation is selected

67

Switching Module for the HV SFCL Project

Main design characteristics

The switching module comprises

3 parallel x 17 series = 51 bifilar pancake coils per phase

Alternating current directions between adjacent turns of bifilar coils cancel most magnetic fields Regions stressed by BIL tests, numbering see next slide

Two in hand winding with 12 mm

wide wire to increase the current

Improved electrical strength due to:

- Insulated wire - New contact design - Corona rings around the coils
(1) (2) (3)

Horizontal stack with radial supports

between module and cryostat wall

(1)

68

Performance Modeling and Testing

Switching

First tests on a 3 m sample of 12 mm wide HTS-wire:

Critical current 167 A @ 77 K, 258 A @ 72 K
77 K, sat., t: 100 ms

More than 60 switching test in saturated (77 K)

and sub-cooled (72 K, 1.2 bar) LN2
2000 Current (A) 1000 0 -1000 T: ~72 K -2000 0 10 20 30 Time (ms) 40 -400 50 400 Voltage (V) 200 0 -200

72 K, 1.2 bar, t: 500 ms

69

Performance Modeling and Testing

Recovery time About 12 - 15 sec measured on full size dummy coil in sub-cooled LN2 12 mm wide dummy wire insulated with wrapped Teflon tape Amount of LN2 available for cooling restricted by appropriate enclosure to simulate adjacent coils
Resistance ratio (%) 110 100 90 80 70 60 -0.05 0 Time (s)
70

T: 77 K, p: 1 bar T: 72 K, p: 1.2 bar

10

20

FCL Termination Design Validation

AC withstand test successfully completed according IEC 60840
- 190kV / 30 minutes

Partial Discharge measurement sucessfully completed (IEC 60840)

- Voltage increase up to 140 kV for few minutes - Decreasing to 114 kV and measurement - No PD measured (noise level < 3pC)

Lightning impulse test successfully completed (IEC 60840)

- 650 kVp (10 shots in both polarity)

Switching impulse successfully completed based on IEEE C57.12.00:

- Success of the test (540 kVp 250/2500s both polarity)

FCL termination high voltage design successfully validated

71

Summary
AMSC is currently advancing the state of the art in
HTS power products
- Worlds First Transmission Voltage HTS Cable in Operation - Worlds First Fault Current Limiting Cable for use in a distribution grid under development - Transmission Voltage Fault Current Limiter under development

72