solutions

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

solutions

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

solutions

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

solutions

Hydra Project Overview

World’s First FCL Distribution Cable to be Installed in Power Grid

• HTS FCL Cable Electrical Characteristics - Design Voltage/Current – 13.8kV, 4000 amp ~96MVA

- Design Fault Current – 40kA @ 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

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Team Roles and Responsibilities

DHS Science &

Technology Directorate

AMSC Prime

Contractor

ORNL Test Agency

DH Industries

Ultera

Altran Solutions

Consolidated Edison

AMSC

System Design

Wire Development

Project Management

Wire Manufacturing

Technical Oversight

Utility Requirements

Construction Management

System Hardware Development

System Planning

Cooling System

Installation Support

Site Design

Permitting

Civil Work

O & M Contract

Cable & Accessory Design

Cable & Accessory

Operational Support

Installation &

Cable Manufacturing

25 m Prototype Cable Test Site

Technical Support

solutions

Fault Current Limiting Cable Operation Principles

Simplified View of Superconductor wire

high resistance layer

zero resistance superconductor layer

switched high resistance superconductor layer

high resistance layer

• Superconductor wire has zero resistance up to the “critical” current

Load Current

Fault Current

Allows the construction of fault current limiting cables

• 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

solutions

Paralleling Urban Buses: The Appeal

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

Typical 2-transformer

urban substations

Paralleling Dense Urban Load Centers Leads to Operational Efficiencies

Total Load ≤60% total transformer MVA Total Load ≤60% total transformer MVA

Typical

Loading

Practice

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Rockview Area Substation

T3

Granite Hill Area Substation

General Electrical Configuration (Existing)

G5

Step-down Transformer

Circuit Breaker

Power flow

13.8 kV Distribution to Yonkers Customers

13.8 kV Distribution to Yonkers Customers

138 kV Transmission

solutions

Rockview Area Substation

T3

Granite Hill Area Substation

General Electrical Configuration (Proposed)

Superconductor 13.8 kV

G5

138 kV Transmission

Step-down Transformer

Circuit Breaker

13.8 kV Sub-transmission to Yonkers Customers

13.8 kV Sub-transmission to Yonkers Customers

Power flow

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Proposed System Layout

Rockview Termination: - Refrigeration - Aux Power and Controls - Series Reactor

Granite Hill Termination

N

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Granite Hill Paralleling Circuit

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Rockview Paralleling Circuit

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Hydra HTS Cable System

Power

Supply

Return

Refrigerator

Heat

HTS Cable

Main Components of HTS Cable Systems

• HTS Cable

• Cryostat

• Terminations

• Cryogenic Cooling System

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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

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Cable Design - Triax® by Southwire

Cryostat Former

Phase 1 Superconductor

Dielectric

Phase 2 Superconductor Dielectric

Phase 3 Superconductor

Dielectric

Copper Neutral

Photo courtesy of Ultera

Triax is a trademark of Southwire

Supply LN2

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25m HTS Prototype Cable Test Setup

Termination

25m HTS Triax® Cable

Refrigeration system

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25m HTS Cable Test LN2 Flow Diagram

Subcooler

V1V2V3

V4V5

LN2 Pump

Triax HTS

Cable

Termination

Termination

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25m HTS FCL Cable Test Plan

25m Prototype

Cable Tests

Dielectric

Tests

Performance

Characteristics

Thermal

Tests

Other

Tests

Cable

Resistance

DC Critical

Current

AC

Loss

FCL

Low Voltage

FCL

High Voltage

Thermal

Stability

Thermal

Cycle

Voltage

Soak

Partial

Discharge

AC

Withstand

Lightning

Impulse

Post-BIL

Partial

Discharge

AC

Withstand

Leak

Check

Post BIL&

FCL DC Ic

Post Thermal

Cycle DC Ic

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25m HTS Cable FCL Test

Measured versus Simulated Results

Symmetrical Fault

-80

-70

-60

-50

-40

-30

-20

-10

0

10

20

30

40

50

60

70

80

0.0000 0.0083 0.0167 0.0250 0.0333 0.0417 0.0500 0.0583 0.0667 0.0750 0.0833 0.0917 0.1000

Time (S)

Cu

rre

nt

(kA

)

Measured Limited Current (kA)

Meas Unlimited Current

Simulated Limited Current (kA)

Measured & Simulated

Limited Current

Unlimited Fault Current

solutions

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

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Hydra Project Phase 1 Achievements

Wire

Development

System Specs

3m Prototype

Cable

25m Prototype

Cable

HTS FCL Cable Qualified for

Power Network

Wire Bulk Properties Verified

Temperature Rise Verified

Over-current Behavior Verified

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

solutions

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

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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 TriaxTM FCL cable

Full Scale Terminations

solutions

Subcooler

V1

V2

V3 V4V5

LN2 Pump

~170m Triax HTS CableTermination

Termination

Primary

Cooler

Back-up

Cooler

Buffer Tank

• DH Industries (Stirling) System

- Modular design uses three (3)

SPC-4 Cryogenerators

• Specification

- 6.2 kW at 72 K (~1kW for

auxiliary loads)

- Pressure drop less than 3 Bar

- 90 liters/minute LN2 flow rate

Hydra Refrigeration System Specification

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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

solutions

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

solutions

Acknowledgment: This material is based upon work supported by the Department of Homeland Security, Science & Technology Directorate, under contract #HSHQDC-08-9-00001. 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.