Hydra Fault Current Limiting HTS Cable to be Installed in the Consolidated Edison Grid

Transcription

1 Hydra Fault Current Limiting HTS Cable to be Installed in the Consolidated Edison Grid J. McCall, J. Yuan, D. Folts, N. Henderson, American Superconductor D. Knoll, Southwire M. Gouge, R. Duckworth, J. Demko, ORNL Z. Wolff, S. Sagareli, Y. Abouyaala, Consolidated Edison 11th EPRI Superconductivity Conference October 28-30, 2013 Houston, TX

2 Outline Hydra Project Primary Objectives Hydra Project Overview Fault Current Limiting Cable Operation Principles Paralleling Urban Buses FCL Cable System Components 25m Prototype Cable Test Results Phase 1 Achievements Phase 2 Status Hydra Project Summary

3 Hydra Project Primary Objectives Develop and Demonstrate Fault Current Limiting HTS Cable to protect critical urban power network infrastructure Phase 1- Develop inherently Fault Current Limiting Cable design - Passed all Industry Qualification tests and engineering studies - Con Edison approved for installation in urban power network Phase 2- System design, installation and 1-year operational demonstration - Site design, construction permitting and system design underway - Operation connecting two Con Edison 13.8kV substations

4 Hydra Project Overview HTS FCL Cable Electrical Characteristics - Design Voltage/Current 13.8kV, 4000 amp ~96MVA - Design Fault Current 67ms Physical Characteristics - Length ~ 170m - HTS Conductor Length ~ 53km - Cold Dielectric, Triax Design Hardware Deliverables - One ~170m Long, 3 Phase HTS Cable - Two 13.8kV Outdoor Terminations - One Refrigeration System - Protection and SCADA Systems World s First FCL Distribution Cable to be Installed in Power Grid

5 Team Roles and Responsibilities DHS Science & Technology Directorate AMSC Prime Contractor ORNL Test Agency AMSC Altran Solutions Consolidated Edison DH Industries Ultera System Design Site Design Utility Requirements Cooling System Cable & Accessory Design 25 m Prototype Cable Test Site Wire Development Construction Management Installation Support Cable Manufacturing Technical Support Project Management Wire Manufacturing Permitting Civil Work O & M Contract Cable & Accessory Installation & Operational Support Technical Oversight System Planning System Hardware Development

6 Fault Current Limiting Cable Operation Principles Load Current high resistance layer zero resistance superconductor layer Superconductor wire has zero resistance up to the critical current Fault Current high resistance layer switched high resistance superconductor layer Simplified View of Superconductor wire AMSC supplies a superconductor wire that instantly introduces high resistance above the critical current Immediate limitation of fault current magnitudes Insertion of resistance decreases X/R and fault asymmetry Allows the construction of fault current limiting cables

7 Paralleling Urban Buses: The Appeal Typical 2-transformer urban substations Typical Loading Practice Total Load 60% total transformer MVA Total Load 60% total transformer MVA Advantages of Paralleled Substations Simple Case Connect additional load without additional transformers or new substations Increases transformer asset utilization Reduces cost of N-1 contingency planning; only 1 transformer required versus 2 Increased interconnectivity protects vulnerable, critical loads in the event of a catastrophic failure Paralleling Dense Urban Load Centers Leads to Operational Efficiencies

8 General Electrical Configuration (Existing) Rockview Area Substation 13.8 kv Distribution to Yonkers Customers T3 138 kv Transmission G5 Power flow Step-down Transformer 13.8 kv Distribution to Yonkers Customers Circuit Breaker Granite Hill Area Substation

9 General Electrical Configuration (Proposed) Rockview Area Substation 13.8 kv Sub-transmission to Yonkers Customers T3 138 kv Transmission G5 Superconductor 13.8 kv Power flow Step-down Transformer Circuit Breaker 13.8 kv Sub-transmission to Yonkers Customers Granite Hill Area Substation

10 Proposed System Layout N Granite Hill Termination Rockview Termination: - Refrigeration - Aux Power and Controls - Series Reactor

11 Granite Hill Paralleling Circuit

12 Rockview Paralleling Circuit

13 Hydra HTS Cable System Heat Power Supply HTS Cable Return Refrigerator Main Components of HTS Cable Systems HTS Cable Cryostat Terminations Cryogenic Cooling System

14 Components of the HTS Cable System Superconducting Cable System - Cable Core Transport the current Limit the fault current Withstand the voltage - Cryostat Insulate thermally keep the cable cold Transport the liquid nitrogen - Termination Connect the system to the grid Manage the transition between cold temperature and room temperature Provide connection to the cooling system

15 Cable Design - Triax by Southwire Phase 1 Superconductor Former Dielectric Phase 3 Superconductor Dielectric Cryostat Supply LN2 Phase 2 Superconductor Dielectric Copper Neutral Photo courtesy of Ultera Triax is a trademark of Southwire

16 25m HTS Prototype Cable Test Setup Refrigeration system Termination 25m HTS Triax Cable

17 25m HTS Cable Test LN2 Flow Diagram Subcooler LN2 Pump V3 V2 V1 Triax HTS Cable Termination Termination V5 V4

18 25m HTS FCL Cable Test Plan 25m Prototype Cable Tests Performance Characteristics Thermal Tests Dielectric Tests Other Tests Cable Resistance Thermal Stability Voltage Soak Leak Check DC Critical Current Thermal Cycle Partial Discharge Post-BIL AC Loss AC Withstand Partial Discharge FCL Low Voltage Lightning Impulse AC Withstand FCL High Voltage Post BIL& FCL DC Ic Post Thermal Cycle DC Ic

19 Current (ka) m HTS Cable FCL Test Measured Limited Current (ka) Meas Unlimited Current Simulated Limited Current (ka) Measured & Simulated Limited Current Unlimited Fault Current Measured versus Simulated Results Symmetrical Fault Time (S)

20 25m Cable and Termination Dielectric Tests - 25m Cable type tests have been completed to a test requirement that was discussed and agreed to by the Team Three phase voltage soak test 15.2kV, 60 minutes Partial discharge measurement in accordance with Southwire s HTS cable standard AC withstand test 37.5 kv, 5 minutes Lightning impulse voltage test ±110 kv, 10 shots Post BIL partial discharge test Post BIL AC withstand 37.5kV, 5 minutes Cable has passed all type tests listed above

21 Hydra Project Phase 1 Achievements System Specs Wire Development Wire Bulk Properties Verified Temperature Rise Verified Over-current Behavior Verified 3m Prototype Cable 25m Prototype Cable HTS FCL Cable Qualified for Power Network Operating Current 4kA Verified Manufacturability Verified Refrigeration Requirements Verified Fault Current Limiting Verified Thermal Stability Verified Manufacturability Verified System Operating Parameters Verified Operating Capacity Verified Dielectric Performance Verified FCL Performance Verified Engineering Models Validated Passed Industry Qualification Tests Con Edison approved for installation between two urban substations

22 Hydra Project Phase 2 Status HTS FCL Cable installation site selected in Westchester County connecting two 13.8kV substations HTS FCL Cable will allow asset sharing of 13.8 kv transformer combined with fault current protection to equipment First-of-kind grid architecture requires new approach to relay protection and tap changer controls Site design and construction permitting progressing Equipment procurement and manufacture underway System control design and integration on-going

23 Hydra HTS FCL Cable Manufacture AMSC provided 53km of HTS FCL wire to Southwire Southwire/nkt cables ( Ultera ) manufacture of HTS FCL Cable underway Cable installation plan in process Cable termination materials on order for integration with cable assembly at substations 25m HTS Triax TM FCL cable Full Scale Terminations

24 Hydra Refrigeration System Specification Primary Cooler Back-up Cooler DH Industries (Stirling) System - Modular design uses three (3) SPC-4 Cryogenerators Buffer Tank Subcooler Specification kw at 72 K (~1kW for auxiliary loads) - Pressure drop less than 3 Bar - 90 liters/minute LN2 flow rate LN2 Pump V1 V2 Termination ~170m Triax HTS Cable Termination V3 V5 V4

25 Hydra Refrigeration System Manufacture Reliability - Redundancy accomplished at component level (modular design) - No first-order single points of failure allowed - Designed with 20% safety margin to the expected losses Manufacture - Electrical design and fabrication completed - Vessels and vacuum-jacketed lines being manufactured - Assembly and factory testing in early 2014

26 Hydra Project Summary HTS FCL Cable passed all Industry Qualification tests 25 meter cable test results validated FCL performance model predictions Equipment procurement and manufacture progressing Below grade construction package out for bid Construction expected to start in early 2014, followed by equipment installation and commissioning tests Operational demonstration will connect two Con Edison substations enabling 13.8kV asset sharing in the power network

27 Acknowledgment: This material is based upon work supported by the Department of Homeland Security, Science & Technology Directorate, under contract #HSHQDC Disclaimer: This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.