ABB – Roger Rosenqvist: August 30, 2012

Cable Systems for EHV TransmissionCable Systems for EHV Transmission

Cable Systems for EHV TransmissionCable Systems for EHV Transmission

Speaker name: Roger Rosenqvist Speaker name: Roger Rosenqvist

Speaker title: Vice President, Business Development

C ( S ) Company name: ABB (Power Systems Division)Raleigh, North Carolina

Cable Systems for EHV TransmissionCable Systems for EHV Transmission ABB is a technology provider, not a developer of transmission

projects. There are many complex issues that arise in connection with the

development and siting of new transmission projects. Some of thosedevelopment and siting of new transmission projects. Some of those issues cover subjects that are outside ABB’s experience and expertise.ABB d t h ffi i t b k d k l d t t ABB does not have sufficient background or knowledge to comment on the reasons as to why a specific technology was chosen by an owner or developer of a new transmission project.

Our presentation will focus on technical characteristics of polymer insulated cable systems, including ABB’s HVDC Light technology, and commercially available capacity ratings for such systemscommercially available capacity ratings for such systems.

We will also discuss recent experiences from the design, construction and operation of cable projects around the world.

Background

N l i i i i ill b d d li i

Background

New electric transmission capacity will be needed to support policies to retire older fossil fuel based power plants, expand access to renewable generation resources and maintain reliability.

Significant public opposition to overhead transmission line construction has raised legal and permitting barriers that can severely delay new projectsseverely delay new projects.

Factors commonly cited against construction of new overhead transmission lines: Aesthetics

Land use constraints

EMF

History of Polymer Insulated Cable Systems for TransmissionHistory of Polymer Insulated Cable Systems for Transmission

1970’s: Deliveries of polymer insulated (“XLPE”) cable systems for voltage ratings up to 145 kV.

1980’s: XLPE transmission cable systems rated 230 kV.

1990’s: XLPE transmission cable systems rated 345 kV, 420 kV and 500 kV.y ,

Typical EHV AC Cable Design (Laminate Sheath)

CONDUCTOR Copper / round, segmented

CONDUCTOR SHIELD Conductive PE

INSULATION- Type Triple extruded, dry cured

Material XLPE- Material XLPE

INSULATION SHIELD Conductive PE

LONGITUDINAL WATER SEALING Swell able tape

METALLIC SCREEN Copper wire

TEMPERATURE MONITORING FIMT in metallic screen

RADIAL WATER SEALING Laminate (Al or Cu) and PE

OUTER JACKET Polyethylene

History of Polymer Insulated Cable Systems for TransmissionMiddleton / Norwalk Project Length: 69 Miles of new 345-kilovolt (kV) line 45 Miles of overhead 24 Miles of underground

Project was energized in Dec. 2008

Typical EHV AC Submarine Cable Design

Conductor material: Copper

Conductor screen material: Conductive PE

Insulation material: Polymer (XLPE)

Insulation screen: Conductive PE

Longitudinal water seal: Swell able tapes

Metallic sheath material: Lead alloy

Inner sheath material: Conductive PE

Assembling: Polymeric profiles

Cable core binder: Polymeric tape

Bedding: Impregnated tape

Armor material: Galvanized steel

Outer serving material: Polypropylene yarn

Typical EHV AC Submarine Cable Design

Conductor material: Copper

Conductor screen material: Conductive PE

Insulation type/material: Dry cured triple extruded XLPE

Insulation screen: Conductive PE

Longitudinal water seal: Swelling tapes

Metallic sheath material: Lead alloy

Inner sheath material: Conductive PEInner sheath material: Conductive PE

Armor material: Copper wires

Outer serving material: Polypropylene yarn

Bayonne Energy Center Project – 345 kV AC Cable Systemy gy j y

Brooklyn

Bayonne Energy Center Project – 345 kV AC Cable Systemy gy j y

Polymer Insulated Cable Systems for HV and EHV TransmissionPolymer Insulated Cable Systems for HV and EHV Transmission

Charging current in AC cables increases cumulatively with distance. (For example, 25 miles of 345 kV XLPE cable requires approximately ( p q pp y600 Amps. charging current.)

Capacity to transmit real power diminishes with distance, limiting the practical length of AC underground and submarine cable transmission circuits.

HVDC bl h i t l d i i ti HVDC cables carry charging current only during energization.

History of Polymer Insulated Cable Systems for TransmissionHistory of Polymer Insulated Cable Systems for Transmission

1970’s: Deliveries of polymer insulated (“XLPE”) cable systems for voltage ratings up to 145 kV.

1980’s: XLPE transmission cable systems rated 230 kV.

1990’s: XLPE transmission cable systems rated 345 kV, 420 kV and 500 kV.y ,

1999: The world’s first polymer insulated cable system for direct current transmission.

Gotland HVDC Underground Cable Project

ApplicationConnect a new onshore wind power facilityIn-Service Year – 1999 Connect a new onshore wind power facility on the southern part of the island to Gotland’s main load centre. Fast reactive power regulation to supportFast reactive power regulation to support integration of wind power facility to the island’s grid.

S l iSolution43 miles long, 160 kV (±80 kV), 50 MW, HVDC underground cable circuit. (HVDC underground cables made it much easier to obtain permits for the new line.)Compact HVDC voltage source converters p gthat provide dynamic voltage support to the island’s AC grid.

ABB HVDC Classic Projects Around the WorldABB HVDC Classic Projects Around the World

Quebec – New England ±450 kV HVDC Line

HVDC Bipole (Traditional Layout for DC OH-Lines)

UDC+ UDC

~~ UDC

Pole conductor

~~ Electrode

UDC

Metallic return conductor

ElectrodeUDC

Pole conductor

- UDC

Sandy Pond 2×1000 MW HVDC Converter Station

Sandy Pond 1000 MW HVDC Converter

World’s First HVDC Transmission – Gotland

HVDC Cable System withHVDC Cable System withMercury Arc Valve Technology

Capacity Rating:Capacity Rating:100 kV 20 MW

Cable Type: Cable Type:Mass-Impregnated Paper (MIND) 1×90 mm2 Cu

Cable Length:100 km (62 miles)

In-Service Year:1954

HVDC MIND Cable Systems for HV and EHV Transmission

Mass Impregnated Non Draining (“MIND”) paper insulation

y

Mass Impregnated Non Draining ( MIND ) paper insulation

Significant submarine HVDC cable technology milestones:

1953 Gotland I: ±100 kV 20 MW 62 miles• 1953 – Gotland I: ±100 kV, 20 MW, 62 miles

• 1968 – KontiSkan I: ±285 kV, 300 MW, 40 miles

• 1989 – FennoSkan: ±400 kV, 500 MW, 124 miles

• 1994 – Baltic Cable: ±450 kV, 600 MW, 155 miles

• 1999 – SwePol Cable: ±450 kV, 600 MW, 143 miles

• 2008 – NorNed Cable: ±450 kV, 700 MW, 360 miles

Due to worker skills and time required for splicing, MIND cable technology is not a practical option for most long distance

d d t i i li tiunderground transmission applications.

Typical Solid Dielectric DC Cable Design

Conductor material Copper or Aluminum

Conductor screen material Conductive PE

Insulation type/material Dry cured HVDC polymer (XLPE)

Insulation screen Conductive PE

Bedding Conductive swelling tapesg g p

Metallic screen Copper wires

Bedding Conductive swelling tapesBedding Conductive swelling tapes

Radial moisture barrier Aluminum-PE laminate

Outer jacket Polyethylene

Typical HVDC Light Submarine Cable Design

Conductor material Copper

Conductor screen material Conductive PE

Insulation type/material Dry cured HVDC polymer (XLPE)Insulation type/material Dry cured HVDC polymer (XLPE)

Insulation screen Conductive PE

L it di l i t b i S lli tLongitudinal moisture barrier Swelling tapes

Metallic sheath material Lead alloy

Inner sheath material Polyethylene

Armor material Galvanized steel wires

Outer serving material Polypropylene yarn

Symmetric Monopole (Typical Layout for DC Cables)

+ UDCPole conductor

~~ 2×UDC (Circuit Voltage)

- UDCPole conductor

HVDC VSC 640 kV (±320 kV), 350-1100 MW

Less than 5 acres

Gotland HVDC Underground Cable Project

ApplicationConnect a new onshore wind power facilityIn-Service Year – 1999 Connect a new onshore wind power facility on the southern part of the island to Gotland’s main load centre. Fast reactive power regulation to supportFast reactive power regulation to support integration of wind power facility to the island’s grid.

S l iSolution43 miles long, 160 kV (±80 kV), 50 MW, HVDC underground cable circuit. (HVDC underground cables made it much easier to obtain permits for the new line.)Compact HVDC voltage source converters p gthat provide dynamic voltage support to the island’s AC grid.

Gotland HVDC Underground Cable Project

Näs converter station

Bäcks converter stationBäcks converter station

Solid Dielectric Cables for HVDC Transmission

1999G

2002 2007-2009QGotland

160 kV (±80 kV)50 MW43 miles

2000

Murray Link300 kV (±150 kV), 220 MW112 miles

2006E Li k

Type and PQ tests2500 mm2 (≈5000 kcmil) Cu or Al640 kV (±320 kV), up to 1100 MW

2013D lWi 12000

Direct Link160 kV (±80 kV) 3×60 MW3×40 miles

EstLink300 kV (±150 kV), 350 MW20 miles (+46 miles subsea)

2009B Wi 1

DolWin1640 kV (±320 kV), 800 MW60 miles (+47 miles subsea)

2015N dB ltBorWin 1

300 kV (±150 kV), 400 MW47 miles (+80 miles subsea)

2012EWIP

NordBalt600 kV (±300 kV), 700 MW31 miles (+248 miles subsea)

2015EWIP400 kV (±200 kV), 500 MW46 miles (+116 miles subsea)

DolWin 2640 kV (±320 kV), 900 MW56 miles (+28 miles subsea)

In the FutureIn the FutureType and PQ tests2500 mm2 (≈5000 kcmil) Cu or Al1000 kV (±500 kV), up to 1700 MW

HVDC Light® projects

Date is when theTjäreborg 2000, 7 MW

Estlink2006 350 MW

Valhall 2010, 78 MW

Date is when the project entered into service, or is scheduled to enter into service.

EWIP 2012, 550 MW

Troll 2004, 2X40 MW

Gotland1999, 50 MW

2006, 350 MWCross Sound 2003, 330 MW

Hällsjön1997, 3 MW

E l P

Directlink

Eagle Pass 2000, 36MW

Caprivi link

Murraylink 2002, 220 MW

2000, 3X60 MW

BorWin 12010, 400 MW

DolWin 12013, 800 MW

Caprivi link2010, 300 MW

DolWin 22015, 900 MW

NordBalt2015, 700 MW

HVDC VSC 640 kV (±320 kV), 350 – 1100 MW

Less than 5 acres

HVDC VSC 640 kV (±320 kV), 350 – 1100 MW

Two-level converter

+ Ud

Cascade connection

IGBT current limit: 1 880 Amp DCIGBT current limit: 1,880 Amp. DC

Power losses: Less than 1%- Ud

HVDC VSC 640 kV (±320 kV), 350-1100 MW

P-Q Diagram

Operating Arear (

p.u.

)Operating Area

Act

ive

Pow

erA

Reactive Power (p.u.)

HVDC VSC Operating RangeHVDC VSC Operating Range

Examples of Existing and PlannedPolymer Insulated DC Cable Projectsy j

Murray Link HVDC Cable Project

ApplicationInterconnection of remote parts of the transmission systems in South Australia and Victoria.

Electricity trading in deregulated power market.

SolutionSolution112 miles long, 300 kV (±150 kV), 220MW, HVDC underground cable circuit.

Compact HVDC voltage source converters that provide dynamic voltage support to the grid.

In-Service Year: 2002

Murray Link HVDC Cable Project

Murray Link HVDC Cable Project

Murray Link HVDC Cable Project

Less than 13 ft. (4 meters)right-of-way widthright of way width

Murray Link HVDC Cable Project

Approximately 400field jointsfield joints

Other Arrangements for Cable Installation

Duct bank system:

Cross Sound HVDC Cable Project

ApplicationApplicationIncreased power transmission capacity between electricity markets in New E l d d L I l dEngland and Long Island.

Solution25 mile long, 300 kV (±150 kV), 330 MW, g, ( ), ,submarine HVDC cable circuit.

Compact HVDC voltage source converters that provide dynamic voltage support tothat provide dynamic voltage support to the grid.

In-Service Year: 2002

Cross Sound HVDC Cable Project

Hew Haven converter station Shoreham converter stationHew Haven converter station Shoreham converter station

Cross Sound HVDC Cable Project

Mid-Atlantic Power Pathway Projectd t a t c o e at ay oject

ApplicationApplicationNew transmission path from Pepco to DPL.

SolutionTwo parallel 43 miles long, 640kV (±320kV) submarine (39 miles) and underground (4 miles) HVDC cable circuits plus approximately 40 miles of HVDC overhead circuit.

Compact on-shore HVDC voltage source converters.

Mid-Atlantic Power Pathway Projectd t a t c o e at ay oject

500 kV Transmission Corridors

Mid-Atlantic Power Pathway Projectd t a t c o e at ay oject

Mid-Atlantic Power Pathway Projectd t a t c o e at ay oject

Mid-Atlantic Power Pathway Projectd t a t c o e at ay oject

Champlain Hudson Power Express (CHPE)Champlain Hudson Power Express (CHPE)

• 1,000 MW buried over 333 miles• Two cables approximately 6

inch diameter• Connecting clean hydro and• Connecting clean hydro and

wind with NYC• Significant environmental

benefitsbenefits• Significant power price reduction

across the state

Source: www.chpexpress.com

Northeast Energy Link (NEL)Northeast Energy Link (NEL)

A feasibility study, completed in 2010, found the NEL to be a highly achievable project based on the significant need for new electric transmission, a positive regulatory environment, proven and reliable DC cable and converter

Source: www.northeastenergylink.com

environment, proven and reliable DC cable and converter station technology, geographic location, and ease of constructability.

The proposed project concept includes:• Direct current (DC) technology that reduces line losses ( ) gy

and is more efficient for long distance electric transmission and underground construction;

• An underground cable circuit extending approximately 230 miles from Orrington, ME to Tewksbury, MA;

• Capacity of 1,100 MW at +/-320kV DC;• AC/DC converter stations on each end;• AC upgrades north of Orrington to collect renewable

energy generated in northern and eastern Maine.

Source: www.atlanticwindconnection.com

BorWin 1 HVDC Cable Project

ApplicationApplicationInterconnection of large off-shore wind generation facility to the German electric

t i i idpower transmission grid.

Solution127 miles long, 300 kV (±150 kV), 400 MW, g, ( ), ,submarine (80 miles) and underground (47 miles) HVDC cable circuit.

Compact off-shore and on-shore HVDCCompact off-shore and on-shore HVDC voltage source converters.

I S i Y 2009In-Service Year: 2009

BorWin 1 HVDC Transmission System – Cable DesignsBorWin 1 HVDC Transmission System Cable Designs

North Sea segment (75 miles)1200 mm2 Cu

Wadden Sea segment (5 miles)Wadden Sea segment (5 miles)1600 mm2 Cu

Underground segment (47 miles)2300 mm2 Al

BorWin 1 HVDC Cable Project

BorWin Alpha converter stationBorWin Alpha converter station

Diele converter station

BorWin 1 HVDC Cable System in GermanyBorWin 1 HVDC Cable System in Germany

Power cables and fiber optic cable in common trenchtrench

Installation of Underground Cable SegmentInstallation of Underground Cable Segment

Installation of Underground Cable SegmentInstallation of Underground Cable Segment

Installation of Underground Cable SegmentInstallation of Underground Cable Segment

Installation of Underground Cable SegmentInstallation of Underground Cable Segment

Mobile splicing unit

I t ll ti f U d d C bl S tInstallation of Underground Cable Segment

Other HVDC Cable Interconnections under Construction in Germany

DolWin1N th S t N th GNorth Sea to Northern Germany

ApplicationApplicationInterconnection of large off-shore wind generation facility to the German electric power transmission

idgrid.

Solution107 miles long, 640 kV (±320 kV), 800 MW, g, ( ), ,submarine (47 miles) and underground (60 miles) HVDC cable circuit.

Compact off-shore and on-shore HVDC voltageCompact off-shore and on-shore HVDC voltage source converters.

In-Service Year: 2013

DolWin 2N th S t N th GNorth Sea to Northern Germany

ApplicationApplicationInterconnection of large off-shore wind generation facility to the German electric power transmission

idgrid.

Solution84 miles long, 640 kV (±320 kV), 900 MW, g, ( ), ,submarine (28 miles) and underground (56 miles) HVDC cable circuit.

Compact off-shore and on-shore HVDC voltageCompact off-shore and on-shore HVDC voltage source converters.

In-Service Year: 2015

Polymer Insulated Cable for HV and EHV Transmission Systems

ABB Kabeldon, Alingsås

ABB High Voltage Cables,Karlskrona

One of the world’s most modern cable factories Extruded cables for AC and DC Submarine and underground systems

Polymer Insulated Cable for HV and EHV Transmission Systems

Huntersville, North CarolinaExtruded cables for AC and DCSame manufacturing process as in KarlskronaFocus on underground cable systemsEmployees – Approximately 120Employees Approximately 120Investment – Approximately $90 millionManufacturing commences in 2012

Polymer Insulated Cable for HV and EHV Transmission Systems

© ABB Group August 30, 2012 | Slide 74