status update for the albany hts cable project · status update for the albany hts cable project...

Status Update for the Albany HTS Cable Project

Chuck Weber, SuperPower, Inc.Shigeki Isojima, Sumitomo Electric Industries

HTS Solutions for a New Dimension in PowerSuperconductivity for Electric Systems – 2007 Annual DOE Peer Review – August 7-9, 2007

2007 DOE Peer Review – 1 –

Presentation Outline

• Program Outline & Objectives• Background information on the Albany Cable Project

• FY2007 Milestones

• FY2007 Accomplishments & Results

• FY08 Planned Performance & Milestones

• Technology Transfer, Collaborations & Partnerships

• Summary


Program Overview

• 350m long - 34.5kV - 800Arms - 48MVA

• Cold dielectric, 3 phases-in-1 cryostat, stranded copper core design

Project Manager; Site infrastructure, Manufacture of 2G HTS wire

Host utility, conventional cable & system protection, system impact studies

Design, build, install, and test the HTS cable, terminations, & joint

Design, construct and operate the Cryogenic Refrigeration System, and provide overall cable remote monitoring and utility interfaceSupported by Federal (DOE) and NY State (NYSERDA) Funds


Site Location

Phase II: 30m YBCO

Phase I: BSCCO


• 3-in-One Cable Design・Compact size (O.D. = 135mm) (5.3”)

• HTS Conductor and Shield Winding・Di-BSSCO wire (Long length, High-Ic, High-

strength, Anti-ballooning)・Equal current distribution to minimize AC loss ・Cancel magnetic field EMI free

• Electrical Insulation・PPLP with high dielectric strength & small tangent loss

• Fault Current Protection・Cu former and shield windings to handle 2nd

contingency fault conditions• Thermal Contraction

・3-cores are loosely stranded to accommodate0.3% contraction

• Thermal Insulation・Stainless steel cryostat for low heat inleakage

• Laying Cable Protection・Stainless steel tension members on OD of cableto carry pulling tension

[Shipping Test Results] Critical Current1.8 kA (at 77K ,DC) same as

designVoltage Test (based on AEIC) AC: 69kV ・10min (no PD)Imp: +/- 200kV, 10 shots/eachAC loss0.7W/m/ph (at 0.8kA) same as

designCable Bending Test (18；1.2ｍR)No Ic degradationNo defect in HTS wires and

electrical insulations

Structure and Properties of Albany BSCCO Cable

HTS Conductor（2-layer）

HTS Shield（1-layer）

Cu Shield

135 mm35 mm

Electrical Insulation（PPLP +Liquid Nitrigen）

Cu Stranded Former

Tension Member

Stainless Steel Double Corrugated

Cryostat

HTS Conductor（2-layer）

HTS Shield（1-layer）

Cu Shield

135 mm35 mm

Electrical Insulation（PPLP +Liquid Nitrigen）

Cu Stranded Former

Tension Member

Stainless Steel Double Corrugated

Cryostat


Cryogenic Refrigeration System: Approach

Cryocooler

Thermosyphon

Liquid NitrogenStorage/buffer

Subcooled liquid nitrogen loop

HTS cable

Hybrid arrangement permits transparent use of bulk liquid nitrogen for back-up

Thermosyphon provides common heat exchange interface between cable and open or closed refrigeration sources


Cryogenic Refrigeration System

Item Specification

Coolant supply tem perature 67 to 77 KTem perature stability +-0.1 K - norm al operation

+-1.0 K - backup operationRefrigeration capacity 5 kW at 77 K

3.7 kW at 70 KM inim um coolant pressure 1 to 5 barg +-0.2M axim um coolant flow rate 50 liter/m in +-1

(excluding CRS)

1.4 m

1.6 m

BOC


Phase I Installation

Cable Installation• Tension : max. 2ton• No cable elongation• No vacuum leakageConventional methods used to install HTS cable


-200

-150

-100

-50

0

50

0 50 100 150 200 250 300 350 400

Cable Length [m]

Tem

pera

ture

[ ℃]

SouthTerm.

0 H

12 H16H

20 H24H

28H34H 2D

3D

9.2D

11.5D 11.6D 11.7D 11.8D 12D 12.4D

0 50 100 150 200 250 300 350

NorthTerm.

Test Items Test Results

System withstand pressure Test 0.61 MPaG (based on ASME code): good

Maximum core tension: approx. 800kgTension minimized by “loosely stranded 3-core structure”

Vacuum level at each part: good (no leakage)Core behavior inside the joint: within the scope of design

2.3kA (dc, defined at 1uV/cm) at 73K Same as the design value

350 m cable section (including joint) : 1.0kWEntire cable system (not including CRS) : 3.1kW

350 m cable section (including joint) : 0.075 MPaclosely matches with the design value (0.07 MPa)

100 kV, 5 minutes, each phase (based on AEIC standard) : good

Initial cooling test

Critical current measurement

Heat loss measurement(under no-load condition)

Pressure drop measurement (Flow rate:50L/min)

DC withstand voltage test

-0.5

0

0.5

1

1.5

2

2.5

0 500 1000 1500 2000 2500

C urrent [A]

Electrical Field [uV/cm]

C ore-1

C ore-2

C ore-3

Ic C riterion（1μV/cm ）

A verage Tem perature : 73K

Summary of Commissioning Tests


Summary of Commissioning Tests

-0.5

0

0.5

1

1.5

2

2.5

0 500 1000 1500 2000 2500

C urrent [A]

Electrical Field [uV/cm]

C ore-1

C ore-2

C ore-3

Ic C riterion（1μV/cm ）

A verage Tem perature : 73K


• 3 Hour Voltage Soak –- Phase Check conducted

• Connect to the Grid at ~ 21:00- Confirm stability of T and P- Shield/Conductor >95%

On-Grid Operations Began July 20, 2006

68

69

70

71

72

73

7/1900:00

7/1912:00

7/2000:00

7/2012:00

7/2100:00

7/2112:00

7/2200:00

7/2212:00

7/2300:00

7/2312:00

7/2400:00

Date and Time, 2006

Tem

pera

ture

[K]

0

2

4

6

8

10

12

14

16

18

20

Tran

smitt

ed E

lect

ricity

[MVA

]

Cable inlet temperature

Cable outlet temperature

Transmitted Electricity

Energization(PM 9:00, July 20, 2006)








• Summary


FY2007 Objectives

The primary objectives for FY2007:

Phase I

1. Monitor and operate Phase I of the cable system remotely from the BOC Remote Operations Center (ROC) for a minimum of 6 months

Phase II

2. Complete the cable design for the YBCO cable

3. Complete fabrication of YBCO wire for the 30 m Phase 2 cable

4. Complete fabrication and factory testing of the 30 m YBCO cable

5. Commence installation of the 30 m YBCO cable


PHASE I320 m & 30 m BSCCO cable manufacture & shipmentHTS cable system installation at Albany test site Commissioning testsEnergization & long-term in-grid operation

Warm-up Removal of the 30 m cable section

PHASE IIComplete design of 30 m YBCO cableComplete fabrication of 9.7 km of 2G wire30 m 2G (YBCO) cable manufacture & shipmentInstallation 2G cable to 30 m sectionAssembling the joint and termination Commissioning testsEnergization & long-term in-grid operation

July 20, 06 – May 1, 07July 20, 06

Current Status of Albany Project

All FY07 Objectives Were Achieved








• Summary


Albany HTS Cable Project Status ReportProject Phase IProject Phase I – 350 m 1G HTS Cable system in 2 sections (320 m and 30 m)Operated without incident or interruption from July 20 thru November 11, 2006

• 114 days or >2,700 hours of continuous operation

Experienced 1st Fault Current Event on November 12, 2006 @ 9:32 AM• Breaker in nearby substation had an external flashover• ~ 7.3 kA peak current on HTS cable• Cable survived without damage, back on-line on Thursday (11/16) @ 12:30 PM

System de-energized and began warm-up: May 1, 2007 • Total accumulated run time: > 280 days (>6,720 hours)• Maintenance work performed on cryocooler, chillers, other equipment without interruption to cable

operations• Zero instances of cable being taken out of service for any HTS cable system issues

Project Phase IIProject Phase II – 320 m 1G HTS Cable joined to 30 m 2G HTS Cable• 2G cable delivered to Albany site, Phase I cable removed• Installation of new cable completed• System will be energized in November 2007


66

67

68

69

70

71

7/20 8/17 9/14 10/12 11/9 12/7 1/4 2/1 3/1 3/29 4/26

Date (2006-2007)

Tem

pera

ture

[K]

0

4

8

12

16

20

Tran

smitt

ed E

lect

ricity

[MVA

]

Cable Inlet Temperature

Cable Outlet Temperature

Transmitted Electricity

Chiller System ShutdownSupply Voltage Issue

Energizedon July 20,2006

Completedon May 1, 2007

Fault Current Event

More Than 6,700 Hrs of Reliable Power Transmission

Summary of Phase I Operation


7kA

8 cycle

The HTS cable system was checked for damage after the fault eventNo Issues Re-connected to Power Grid

Summary of Phase I Operation


-200

-150

-100

-50

0

50

0 100 200 300 400 500 600 700 800Position [m]

Tem

pera

ture

[ ℃]

30m HTS Cable320m HTS Cable

350m Return Pipe

12H

1D

3D

5D

7D

9D

11D

14D

21D

SouthTerm

NorthTerm

Before warming-up,• Megger Test• Ic Measurements

Warm-up Process,(1) LN2 pumped into the CRS bulk storage tank(2) Remaining LN2 in system allowed to evaporate naturally

No Change

Vacuum level• No leakage

Cable Tension• Returned to theoriginal value

(approx. 200kgcompressive force)

Commencement of Phase II


Design of YBCO Cable (3-in-One Type)

BSCCO cable YBCO cable

HTS wire 2 layers 3 layers

Former Stranded Cu wires with insulation （φ16 mm / 140 mm2）

Electric insulation PPLP (thickness 4.5 mm)

HTS shield 1 layers 2 layers

Protection layer Copper tapes

Core outer diameter 35 mm 35 mm

Cu StrandedWire Former

Electric Insulation(PPLP + Liquid Nitrogen)

Stainless Steel DoubleCorrugated Cryostat

Cu ShieldSuperconducting Shield(2 Layers)

Superconductor(3 Layers)

135 mm


Items SpecificationDimension Width: 4.1±0.5mm / Thick: 0.10±0.02mm

Piece length 42.6 m (33pcs) / 44.0 m (192pcs)

Total Amount 9.6 km

Ic / n-value Min Local Ic: 40AMin Local N-value: 15

Average Min Ic :Approx.70A

Tapes were fully qualified for Ic, thickness, width, n-value, and hermeticityAverage minimum

Phase II: Fabrication of 9.7-km of 2G Wire

Ic of 225 segments each 42.4 to 44 m long = 70 A Over 56% of 225 segments have minimum Ic over 70 AAverage end-to-end Ic will be higher (~ 2x spec of 40 A)Average minimum n-value of 225 segments = 24 56% of 225 segments have minimum n-value over 25

Demonstrated availability of 2G from a qualified Manufacturing Operation!

0

10

20

30

40

50

60

70

80

# ta

pes

10 - 15 15 - 20 20 - 25 25 - 30 30 - 35 35 - 40Minimum n-value over 42 to 44 m (A)

0

10

20

30

40

50

60

# ta

pes

40 - 49 50 - 59 60 - 69 70 - 79 80 -89 90 - 99 100+

Minimum Ic over 42 to 44 m (A)


10 m Test Cable Fabrication with 2G WireConductor Layer Shielding Layer

Good winding performance without any Ic degradation


1 m Test Core Sample with 2G WireItems Specification

Former Cu wires stranded/16mm

HTS Wire 3 layers

Dielectric PPLP – 4.5mm

HTS Shielding 2 layers

Protective layer Cu tape, Kraft paper

Outer Diameter 34.5mm

Critical Current Measurement : YBCO Core Sample

-1

0

1

2

3

0 500 1000 1500 2000 2500Current [A]

Ele

ctric

Fie

ld [u

V/cm

]

YBCO ConductorYBCO Shielding

Test Items ResultsCritical Current

(at 77K, 1uV/cm)

1.42kAdc (Conductor)

1.97kAdc (Shielding)

AC Loss

(at 800Arms, 60Hz)

0.4W/m/Core

Test Results

Design Ic1.5 kA-dc (conductor)1.9 kA-dc (shield)


Fault Current Test with 1 m 2G Sample CableFault Current Testing• Sample: BSCCO Core – YBCO Core

(Compare YBCO core with BSCCO one) • Current: 23kA• Duration: 8 – 38cycles• Cooling: Open Bath (77K)

Test Site : Nissin Electric (Kyoto)

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50Duration [cycles, 60Hz]

Max

imum

Tem

pera

ture

Ris

e [K

]

BSCCO ConductorBSCCO ShieldYBCO ConductorYBCO Shield

Shield

Conductor

Generator(5000V)

Lg

L1 L2 L0Transformer(6600V/550V)

Test SamplesSWGenerator(5000V)

Lg

L1 L2 L0Transformer(6600V/550V)

Test SamplesSW

Temperature Rise During Faultnearly identical to BSCCO core


[YBCO tape winding process] [3 cores stranding process]

YBCO cable was fabricated under nearly the same conditions as the BSCCO cable

Fabrication of the 30 m YBCO Cable


Manufacturing of 30 m YBCO cable completed in March!

Critical Current• Conductor : 2660 – 2820A (DC) at 77K• Shield : 2400 – 2500A (DC) at 77K

AC Loss• 0.34W/m/phase at 0.8kArms, 60Hz

Bending Test (18D: Bending Dia. = 2.4 m)• No Ic degradation• No defect was found at dismantling

Inspection

Voltage tests (Based on AEIC)AC 69kV for 10 minute, Imp ±200kV, 10 shots/eachDC 100kV for 5 minutes

The following shipping tests were conducted successfully on samples from long cable

YBCO Cable Fabrication & Shipping Test


-0.5

0

0.5

1

1.5

2

0 500 1000 1500 2000 2500 3000Current (A, DC)

Elec

trica

l Fie

ld(u

V/cm

)

Core-1Core-2Core-3

Ic Criterion (1uV/cm)

-0.5

0

0.5

1

1.5

2

0 500 1000 1500 2000 2500 3000Current (A, DC)

Elec

trica

l Fie

ld(u

V/cm

)

Core-1Core-2Core-3

Ic Criterion (1uV/cm)

Sample: 3 meter 3-Core

Ic (Conductor) = Approx. 2660 – 2820A (DC, 77K, 1uV/cm)

Ic (Shield) = Approx. 2400 – 2500A (DC, 77K, 1uV/cm)

Conductor Shield

Very good match between test results and design values

Critical Current Measurement


0.001

0.01

0.1

1

100 1000 10000Loading Current (Arms, 60Hz)

AC

loss

(W/m

/pha

se)

Measured value

Sample : 2.5 meter single coreCurrent loading : go & return through conductor and shieldMeasuring : Lock-in amplifier with electrical 4 terminals

0.34 W/m/ph @ 800 ArmsSlightly better result than the

1 meter test sample core

AC Loss Measurement


YBCO Cable Shipment

Departure from the Port of Kobe

(May 8, 2007)

Shipping from SEI Osaka Works (April 26, 2007)


Disassembly of Joint

Disassembly work at Termination Removal of the 30 m BSCCO cable has been completed!

Phase II: 30 m BSCCO Cable Removal


Installation of 30 m YBCO Cable


FY2007 Objectives:The primary objectives for FY2007:

Monitor and operate Phase I of the cable system remotely from the BOC Remote Operations Center (ROC) for a minimum of 6 months

Phase I operated for >9 months with no outages due to issues related to the HTS system

Complete the cable design for the YBCO cable

Slight alterations from BSCCO cable design incorporated into YBCO cable design

Complete fabrication of YBCO wire for the 30 m Phase 2 cable

9.7 km of 2G wire fabricated and tested last fall

Complete fabrication and factory testing of the 30 m YBCO cable

30 m YBCO cable fabricated and passed all FAT by March 07

Commence installation of the 30 m YBCO cable

Phase II began on May 1, YBCO cable installed and being connected








• Summary


FY 2008 Plans

Complete installation and pre-commissioning testing of the YBCO/BSCCO cable

Complete the cooldown process of the cable system and begin online operation of Phase II

Monitor and operate the cable system throughout GFY08

Additional Items

Push stakeholders to support longer term on-grid operation

Continue promotion and technology transfer of HTS cable technology

Continue support for the HTS Cable Collaborative








• Summary


Technology Transfer, Collaborations & PartnershipsPresentations• ASC ’06 – Seattle, WA – 8/28-9/1/06

• EPRI S/C Workshop – Columbus, OH 9/13-14/06

• Tech Valley Chamber Executive Institute –10/22/06

• Leadership Tech Valley Group – 10/23/06

• DOE Wire Workshop – Panama City, FL 1/16-17/2007

• IEEE Schenectady Chapter – 1/19/07

• HTS Cable Collaborative Meetings

• IEEE PES General Meeting – Tampa, FL–6/25-28/07

• ISIS-15 (Erlangen, Germany) – 9/27-29/06

• N

• K– 1

• D(Nashville, TN) –

• S

• Q

• N(Washington, DC) –

• H2007

• R

• C

o. Colonie HS Technology Night – 10/16/06

nolls Atomic Power Lab (Schenectady, NY) 0/31/06

efense Manufacturers Conference 11/27-29/06

CCC Technology Club – 1/26/07

uestar III METS Program – 1/31/07

ational Electricity Delivery Forum 2/22/07

annover Fair (Hannover, Germany) – April

PI Alumni Group – 6/19/07

EC/ICMC (Chattanooga, TN) – July 2007


Tours, Events and News ArticlesTours & Events• Phase I Commissioning Ceremony – 8/2/06• Phase II Kick-Off Event – 5/2/07• Tours of the ACP site were conducted for 12 different organizations• (8) different countries represented

News Articles• T&D World Article – March 2007 “Superconducting Cable Connects the Grid”• Times Union – 3/4/07 “SuperPower plans for amazing future”• Times Union – 5/3/07 “Project comes down to the wire”• Elektronik – 10/2007 “Energie sparen durch Kaelte”• Christian Science Monitor – 12/12/06 „Electric breakthrough goes commercial“• Daily Gazette – 12/22/06 “SuperPower ships first of new wire”• The Business Review – 12/20/06 “SuperPower announces first major superconducting wire shipment”• Power Magazine – October 2006 “First live superconducting cable”• T&D World – 8/24/06 “High-Temperature Superconducting Cable Project is On-Line in Albany, New

York”• Wire & Cable International – 8/14/06 “Albany cable project now online” & “Three-to-five times more

power”• Times Union – 8/3/06 “Cool cable line put to test”• Business Review – 8/2/06 “$27M cable project commissioned”• Daily Gazette – 8/3/06 “Officials celebrate start of power test”








• Summary


Presentation SummaryWorld class team has successfully executed on Phase I of the program

Met or exceeded all goals and objectives

Cable ran flawlessly for >9 months with ZERO instances of downtime due to the HTS system

Efficient, reliable and robust design capable of handling ‘real-world’ utility operating environment

ALL equipment/systems responded as designed without any adverse effects

Biggest reliability concern (CRS) addressed & proven to meet commercial requirements

On track to successfully implement Phase II of the program

World’s first in-grid demonstration of a YBCO device

Technology transfer & education achieved by numerous tours/events (14), articles (14) an presentations(18) given throughout the year


Thank you!

status update for the albany hts cable project · status update for the albany hts cable project...

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