Progress in Scale-up of 2G HTS Wire at SuperPower Part III

Transcription

1 superior performance. powerful technology. Progress in Scale-up of 2G HTS Wire at SuperPower Part III V. Selvamanickam & Y. Xie Y. Chen, X. Xiong, M. Martchevski, Y. Qiao, A. Rar, B. Gogia, R. Schmidt, A. Knoll, and K. Lenseth DOE funding through Title III Program & UT-Battelle Leveraged funding from AFRL. Supported by CRADAs with Los Alamos, Oak Ridge, & Argonne National Laboratories FY28 Superconductivity for Electric Systems Peer Review, Arlington, VA, July 29 31, 28 SuperPower, Inc. is a subsidiary of Royal Philips Electronics N.V.

2 Meeting customer performance requirements for joints: mechanical robustness proven in Production Mode A customer required 1,2 m of 2G wire with 11 splices for a coil application. The Ic of entire wire length and resistance of all splices had to be tested after splicing. A production operation was developed to make consistently high-quality splices Also, the mechanical robustness of splices had to be established since the spliced wire had to be moved through 4 and 2 diameter rollers in the 5 m transport Ic measurement rig at a speed of up to 4 m/h Roller A (4 ) Roller D (4 ) Roller B (4 ) Roller C (4 ) Roller F (2 ) Roller E (4 ) Roller G (2 ) Voltage (Volt) 4.E-5 3.5E-5 3.E-5 2.5E-5 2.E-5 1.5E-5 1.E-5 1st test After running thru 4" roller 3 times After running thru 2" rollers 6 times Current (A) 2

3 Ic measured every 5 meters over 1,218 m of wire with 11 splices Location of joints Ic (A) Position (m) Arrangement of the 12 segments along the length was decided based on communication with customer so that the Ic profile fitted the needs for coil winding. 3

4 I-V curves of the 11 sections containing the splices 6.E-4 g Voltage (Volt) 5.E-4 4.E-4 3.E-4 2.E-4 Joint#1: 7-75m Joint#2: m Joint#3: m Joint#4: m Joint#5: m Joint#6: m Joint#7: m Joint#8: m Joint#9: m Joint#1: m Joint#11: m 1.E-4.E+ -1.E Current (A) All 11 splices show smooth transition at their respective Ic. 4

5 Excellent resistance measured in all splices 6.E-5 Voltage (Volt) 5.E-5 4.E-5 3.E-5 2.E-5 Joint#1: 7-75m Joint#2: m Joint#3: m Joint#4: m Joint#5: m Joint#6: m Joint#7: m Joint#8: m Joint#9: m Joint#1: m Joint#11: m 1.E-5.E+ -1.E Current (A) All but one of the splices showed a resistance around 33 nω, One splice showed a resistance of 1 nω, still within limit. 5

6 Customer-driven development of insulated wire Several customers, primarily for coil applications, required insulated 2G wire After evaluating a number of vendors, we procured a system for in-house fabrication of insulated wire System in place used for both 12 and 4 mm wide wires Deliveries of insulated wire already being made 6

7 Wire quality is confirmed after insulation After insulation, wire is not accessible for transport current measurements every 5 m in reel-to-reel test rig. Non-contact Ic technique used to confirm the quality of wire after insulation 7

8 FCL prototype with 2G wire: In FY6, we successfully completed testing at KEMA high-power test facility 12 elements, 4 cm long with four 2G tapes in parallel per element Current [ka] Time [ms] 2G SFCL Voltage across HTS elements [kv] Iprospective I_total_KEMA I_HTS Ish V_total_KEMA High-power SFCL test Prospective current Limited current Current through element Response time Element quality range 2G 9 ka* 32 ka 3 ka < 1 ms Narrow Superior performance in all respects using 2G SFCL in High-power tests *AEP s requirement of 26 ka rms (7 ka peak) fault condition is satisfied with this 2G performance Needed to satisfy AEP requirement of Recovery Under Load (RUL) Copy of KEMA Trial 37.mpg 8

9 FY8 Testing of FCL with 2G wire for Recovery Under Load (RUL) Transmission voltage level FCL being developed by SuperPower in DOE-SPI/SPE program for installation in AEP s TIDD substation Specifications Prospective fault current is 13.8 ka rms (~37 ka peak ) Load current 12 A-rms, 138 kv Recovery Under Load (RUL) FCL has to recover with 1,2 A load current SuperPower s 2G wire assembled in a matrix design and tested at KEMA s high power test facility in May & June 28 Test conditions 37 ka fault 5 cycles fault, 18 cycles load, 5 cycles fault 9

10 RUL with 9% of the Power Recovered Within the Second and Third 37kA Faults 1

11 Wire deliveries: In FY7, 3 m cable was manufactured by Sumitomo Electric with ~1, m of SuperPower 2G HTS wire 2G wire cable winding 3 core stranding Cu Stranded Wire Former Electric Insulation (PPLP + Liquid Nitrogen) Stainless Steel Double Corrugated Cryostat 135 mm 2G HTS wire (3 conductor Layers) 2G HTS wire (2 shield Layers) Cu Shield 11

12 2G cable was installed, connected to 1G cable section and fully tested by end of 27 Installation at Albany Cable site (Aug. 5, 27) Joint made between 32 m 1G cable & 3 m 2G cable 2.5 Complete 35 m cable tested Ic = at 23 A, same as factory test performance of 2G cable section Electric Field [uv/cm] C ore-1 C ore-2 C ore-3 C able M ean Tem p :73K Ic critrion (1μV/cm ) 69K Current [A, DC] 12

13 Demonstration of the world s first device with 2G HTS wire in a live power grid 1.2 Temperature Deference between Outlet and Inlet of Cable 2 Temperature Deference [K] Jan Transmitted Electricity [MVA] Transmitted Electricity 1/7 1/21 2/4 2/18 3/3 3/17 3/31 Date (28) Cable made with 2G HTS wire was energized in the grid in January 28 & performed without any issues 13

14 Our 2G wire has gained worldwide acceptance for a variety of applications In FY8, 47 unique customers procured 33, meters of 2G wire in 77 orders This is a 5-fold increase in wire orders in FY7 (6,4 m) To-date, we have 58 customers from 16 countries In addition to long lengths, high Ic and meeting application-specific requirements, we strive to increase 2G wire acceptance by reducing cost & increasing production capacity. Price of 2G wire has been reduced to $ 4/m from $ 65/m last year. Cost reduction through processing of longer lengths, improved yield, reduced vendor costs USA 21% Asia 33% New Zealand 1% Brazil 3% Europe 42% 14

15 Reducing wire cost by QC for high-yield manufacturing: Uniformity of long lengths monitored by multiple techniques at all stages 8 15 IBAD MgO RGB data 6 LMO in-plane texture LMO RGB data 2 Substrate defect density Absolute Position (meters) Color (RGB) variations along tape length are accurate indicators of variations thickness of buffer layers & in turn the stability of the buffer processes 15

16 On-line tape inspection system in Pilot MOCVD is used to correlate Ic of long tapes to tape surface features Good region Defective region Ic (A) Tape position (m) MOCVD defect density 16

17 Correlation of Ic drop to substrate defect identified in tape inspection 6 12 Substrate inspection m m 5 1 Critical current (A) Transport Ic Non contact Ic Defect density Defect Density Final buffer (LMO) inspection Tape position (m) HTS layer m m 17

18 On-line XRD system for Pilot MOCVD New on-line XRD system for Pilot MOCVD designed and constructed to rapidly discern (6)/(2) peak intensities over the length of moving tape during YBCO deposition Ic (A/cm) YBCO (2)/(6) ratio 18

19 XRD system successfully tested in high-speed off-line mode on over 25 m of YBCO tape Peak intensity Lin (Counts) MgO substrate YBCO (6) Data from GADDS XRD system in 18 seconds ; Cu anode YBCO (6) YBCO (2) counts MgO theta (degrees) YBCO (6) Data from same segment within 1 second in new XRD system; Cr anode (6), (2) peak intensities obtained over 25 m YBCO tape at speed of 1 m/h Measurement 19