development and commercialization status of hts cable...

Development and Commercialization

Status of HTS Cable System in Korea

LS Cable & System

Superconducting Cable Business Task Force Team

Jin Bae Na, Ph.D.

Oct. 30, 2013

Development of HTS Cable in Korea ► R/D program in Korea

► Overview of LS CNS Status

Demonstration of 22.9kV/50MVA HTS Cable System


Future Plan

Development of 80kV/500MW HTS Cable System

’01 ’02 ’03 ’04 ’05 ’06 ’07 ’08 ’09 ’10 ’11 ’12 ’13 ’14 ’15 ’16

Developing

22.9kV

/50MVA

30m (1-Φ)

Carrying out

Int’l Certification &

Long-term Test

22.9kV/50MVA

100m

Progressed

154kV/1GVA

100m

MEST1)

Developing

22.9kV

/50MVA

30m (3-Φ)

Demonstration

in Actual Grid

Actual Grid

(ICHEON S/S)

22.9kV/50MVA

500m

Actual Grid

(ICHEON S/S)

22.9kV/150MVA

100m

Actual Grid

(JEJU Island)

DC 80kV/500MW

500m

Basic

R/D for

DC

200kV

MKE2)

Developing

DC 200kV/5GW

Demonstration

in Actual Grid

Actual Grid

(JEJU Island)

154kV/500MVA 1km

DAPAS3) Program

Commercial

Target 1)MEST: Ministry of Education, Science & Technology 2)MKE: Ministry of Knowledge & Economy 3)DAPAS: Development of Advanced Power System by Applied Superconductivity Technologies

Pilot

Project

3/Page

4/Page

AC

22.9kV

▪ 50MVA Completing Commissioning & Demonstration in 2011

▪ 150MVA Ongoing Development & Demonstration till 2013

154kV

▪ 1GVA Completing Development & Long term Test in 2011

▪ 600MVA Ongoing Development & Demonstration till 2016

DC

80kV

▪ 500MW Completing Development in 2013

200kV

▪ 5GW Completing Basic R/D in 2011

Planning Development and PQ test till 2016

via National and In-house Projects

Development of HTS Cable in Korea

Contents

Demonstration of 22.9kV/50MVA HTS Cable System ► Components

► Installation

► Operation

Future Plan



6/Page

1

2

3

4

5

22.9kV/50MVA HTS Cable

Termination

Joint Bay

Cooling System

Offset System

1 2 3 4 5

Air view of HTS Cable System in Icheon S/S

Bending point: total 9 with 90° bending angle

7/Page

KEPCO Icheon Substation

Electrical Characteristics

- Nominal Voltage: 22.9kV

- Rated Current: 1.25kA

Physical Characteristics

- Cable Length: ~ 500m

- Cold Dielectric Design

- 3 phases in One Cryostat

- HTS wire: YBCO Coated Conductor

Hardware

- 300m and 200m HTS Cable

- Outdoor Termination (3-Φ in 1 Cryostat)

- Joint bay (3-Φ in 1 Cryostat)

Installation/Commissioning: July 2011

Grid Application: Aug. 19, 2011

Overview of HTS Cable System in Icheon S/S

8/Page

Design

- Cold Dielectric

- Outer Diameter: 151mm

- Seamless Al Cryostat

- PVC Sheath

- Insulation Level up to 35kV Grade

Coverable range: 13.2kV ~ 35kV

- 3-core type Seamless Al Cryostat

- Fault Current By-pass with Stabilizer

Characteristics

Specification

- 22.9kV (Nominal), 13.2kV (Phase)

- 1,260A (50MVA)

- Short Circuit Rating: 25kA/30cycle (Cu Stabilizer)

- Application of Cryogenic System (Open-loop type)

HTS Cable

9/Page

Joint Bay

Compact Design

(500mm Ø, 3.5m L)

Insulation Level up to 35kV Grade


Pre-fabricated components

Maximum Operating Pressure: 15bar

Termination

Compact Design

3-Φ in one cryostat (22.9kV)

Maximum Operating Pressure : 15bar

Pre-fabricated components

Polymer composite Bushing

Pre-fabricated

•Jointing at site

Pre-fabricated

Termination & Joint

10/Page

Buffer for balancing System pressure

and fault current

Overview

Cooling system

Open-loop type using Decompression unit

Capacity: 6.5kW @ 69K

11/Page

Item Specification

Operating

Condition

Inlet Temp. of Cable 69K

Inlet Temp. of Cable 73K

Circulation Flow rate of LN2 0.5kg/s

Pressure 3barG ~ 7.5barG

Fault Current 25kA, 30cycles

Heat Load

Cable & Termination 4,100W

Cooling System 800W

Difference of

Pressure

Cable & Termination 1.4bar

Cooling System 1.1bar

Specification

Cooling system

12/Page

Photos of 22.9kV/50MVA Cooling System

Cooling system

Open-loop type

- Decompression Unit

Heat exchanger in decompression cryostat

Vaporizer and decompression pump

13/Page

Manufacturing

HTS Cable

Stranding of

Former

Former is wound up

using stranding

machine. The

diameter and the

surface of former

should be controlled

precisely to make

even and uniform

shape of HTS wires

Wrapping &

Cushion Layer

Stainless steel and

carbon paper tapes

shall be wound to

bind the former

according to the

designed diameter

Stranding of HTS &

Conductor Screen

HTS wires and LPP

papers shall be

wound over the

cushion layer, which

will be controlled

together using

stranding machine

modified for HTS

cable

Electric Insulation

& Insulation Screen

During the lapping of

LPP papers, tension

shall be carefully

controlled for

insulation quality and

bending characteristic

Inner Cryostat

The height and pitch

of corrugated Al

cryostat is critical to


Vacuum

Conditioning

The vacuum region

between inner and

outer cryostat of the

cable shall be

subjected to vacuum

pumping for at least

30 days at a

temperature of 30℃

MLI Taping

After cleaning the

surface of inner

cryostat, MLI is

wrapped and 4 Teflon

spacers shall be

stranded on the

surface of MLI

Outer Cryostat

The height and pitch

of corrugated Al

cryostat is critical to


Outer Jacket

During the extrusion,

cable diameter is

measured by X-ray

scan

14/Page

Test Details Result

22.9kV 50MAVA HTS Cable 30m

Proto type test (2005)

- Long term test (load cycle test)

Pass

- DC critical current Pass

- Withstand voltage test Pass

- AC loss measurement Pass

- Long term test (cool down test) Pass

- Summary of the test results

22.9kV 50MVA HTS Cable 100m

type test (2007)

- Cable bending test Pass

- Load cycle

(cooling circuit and Cryostat pressure check) Pass

- Thermal cycle (shrinkage of cable) Pass

- Dielectric loss factor (Tan δ) Pass

- Dielectric security Pass

- Partial discharge Pass

- DC critical current Pass

- Visual inspection of HTS cable sample Pass

HTS Cable

Type Test on previous proto-type of 22.9kV/50MVA

Evaluating Unmanned Operation System for Cooling System

No. Item Specification

1 MS(Master Station) • Notifying Alarm and trip to the SCADA and User by E-mail and SMS.

2 CS(Control System) • Communicating with REM, DUM and Cryogenic Refrigerant by profibus

3 REM(Reservoir Module) • Controlling Reservoir Module Independently by PLC.

• controlled by CS and Communicating with CS.

• DUM and Cryogenic Refrigerant: Operated by the Temp. of the HTS Cable. 4 DUM(Decompression Unit Module)

5 Cryogenic Refrigerant

6 LTS(Load Termination System)

• Explosion-proof type(IP 55)

• Controlled by CS and Communication with CS. 7 JBS(Joint Bay System)

8 STS(Source Termination System)

LTS JTS STS REM PLC

DUM PLC

Control Net ProfiBus

Ethernet

HMI (Server PC) HMI (Client PC) Local Network

User Date Acquisition

Input

Control Value MS

PLC duplex configuration (watchdog, quick change when Failed)

Control system

15/Page

Level Action countermeasure

3 Engineers standby within 24hrs Sending SMS to people in charge

2 Alarming for observation to decide cutting power or not

Engineers standby within 5hrs & Clearing alarms after measures

Informing to 2nd line of SCADA

Sending SMS to people in charge

1 Stopping the operation: Cutting power Informing to 1st line of SCADA

Sending SMS to people in charge

Action Plan According to Fault Level

Condition for Deciding Faults

Control system

16/Page

Step Level Deciding Faults Setup Maintaining

Time

1

1

Breakdown Fulfilling conditions: Inner pressure of Reservoir & Load-side termination Under 2barG 10sec.

2 Fire Installing the fire alarm in Cooling room and Joint room

3 Explosion &

Damage of

HTS wire

Fulfilling conditions: Inlet temp. of cable (2 points), Joint (2 points) Over 75K 10sec.

4 Fulfilling conditions: Pressure of outlet of circulation pump & source-side termination Over 6.5bar G 0.5sec.

5

2

Breakdown Fulfilling conditions: Inner pressure of Reservoir & Load-side termination Under 2.5barG 10sec.

6 Explosion &

Damage of

HTS wire

Fulfilling conditions: Inlet & Outlet temp. of cable (4 points), Joint (2 points) Over 73K 20sec.

7 Fulfilling conditions: Pressure of outlet of circulation pump & Source-side

termination Over 6bar G 5sec.

8

Maintaining

Cooling

system

Flow rates of LN2 Under 0.2kg/s 10sec.

9 Fulfilling conditions: Vacuum condition of cable, joint & termination Over 0.1torr 10sec.

10 Fulfilling conditions: Inner pressure of pneumatic tank Under 4.2bar 10sec.

11 Fulfilling conditions: Level of LN2 tank Under 15% 10sec.

12 3 Whole

system Informing people in charge after checking malfunction or abnormality of all sensors

Item Standard Spec. Result

1 DC Voltage Test (Jacket) IEC 60840 10kV for 1min. Pass

2 Heat Loss Measurement LS Standard 3.5W/m Pass

3 DC IC Measurement KS C 6111-6 3.27kA@70K Pass

4 AC loss Measurement LS Standard 1.25W/m/Phase Pass

5 DC Voltage Test KEPCO Standard 46kV for 10min. Pass

6 Visual Inspection LS Standard Drawing Pass

Test Specifications and Results

the world’s first experience to measure AC loss at rated current (1,250A)

in actual power grid

17/Page

18/Page

Trend of Load Current vs. Quantity of Heat Capacity

1-day trend during Increasing

Load Current to 600A

20 months trend from starting

demonstration

Starting Demonstration: Aug. 19, 2011

- Load current: 300A (connected to 2 D/L)

Increasing Load Current: Oct. 6, 2011 - Present load current: 600A ~700A (connected to 5 D/L for full load)

At peak time (winter), load current was around 900A.

Momentary build-up due to loop current at connecting 5 D/L

Oct. 6 Oct. 7 Aug. 19 Mar .31

19/Page

Trend of vacuum

20 months trend from starting

demonstration

- Very stable the degree of vacuum

- Under 6.0E-6 torr

HTS cable length of 22.9kV/50MVA

- 500m (Two span : Connection with joint bay)

Operation period - Total 20 months

- Unmanned operation during18 months

8-1-2011 12-1-2011 4-1-2012 8-1-2012 12-1-2012 4-1-20131E-8

1E-7

1E-6

1E-5

1E-4

1E-3

0.01

0.1

1

Va

cu

um

[to

rr]

Date

Cable span 200m

Cable span 300m




► Component

► Installation

Future Plan

Demonstration of 80kV/500MW HTS Cable System

21/Page

22.9kV/150MVA HTS Cable

Termination

Cooling System in Container

U-bending area

1

2

4

3

1 2 3 4

Air view of HTS Cable System in Icheon S/S

22/Page

KEPCO Icheon Substation

Electrical Characteristics

- Nominal Voltage: 22.9kV

- Rated Current: 3.75kA

Physical Characteristics

- Cable Length: ~ 100m

- Cold Dielectric Design

- 3 phases in One Cryostat

- HTS wire: YBCO Coated Conductor

Hardware

- Compact cooling system in 40ft container house

- Outdoor Termination (3-Φ in 1 Cryostat)

Installation/Commissioning: October 2013

Grid Application: Nov. 01, 2013

Overview of HTS Cable System in Icheon S/S

23/Page

Design

- Cold Dielectric



- PVC Sheath

- Insulation Level up to 35kV Grade


- 3-core type Seamless Al Cryostat


Characteristics

Specification

- 22.9kV (Nominal), 13.2kV (Phase)

- 3,750A (150MVA)

- Short Circuit Rating: 25kA/30cycle (Cu Stabilizer)

- Application of Cryogenic System (Hybrid type)

HTS Cable

24/Page

Overview

Cooling system

Hybrid type : Close loop + Open loop

- Using 4kW Stirling refrigerator

- Using decompression unit

Capacity: 10kW @ 69K

Seperator Filter Unit

PCS (Pressure Control System)

CP (Circulation Pump) Unit DC (Decompression)

Unit

25/Page


Future Plan


Development of 80kV/500MW HTS Cable System ► Component

► Installation

► Operation


26/Page

80kV/500MW HTS Cable

Outdoor Terminations

Joint Bay

Offset System

E

2

1

1

2

3

3

E

Photo of KEPCO power testing site in Gochang

27/Page

Design

- Cold Dielectric



- PVC Sheath

- Insulation Level up to DC 200kV

: Coverable Range : DC 80 ~ 200kV


Characteristics

Specification

- 80kV (Nominal)

- 3,125A (500MVA)

- Short Circuit Rating: 6.25kA/30cycle (Cu Stabilizer)

- Application of Cryogenic System (Close-loop type)

HTS Cable

28/Page

HTS Cable

Jointing

& Assembling Cryostat

Vacuum exhausting

& Assembling Bushing

24hr Positive Load cycle

test

Leak test Pressure test

24hr Polarity reversal test 48hr Positive Load cycle test S/I Switching Imp. test

- Recommendation

: Electra 219/189

- Test voltage

: Uo ± 285kV

S/I Lightning Imp. test

Warm-up

- According to Cigre W/G

B1-31

- Recommendation

: Electra 219

- Test voltage : ± 1.45Uo,

8cycles

- 1x10-8 mbar•ℓ/sec

Cool - down 24hr Negative Load cycle

test

Special test

Long term reliability test

- Recommendation

: Electra 219

- Test voltage

: 1.85Uo, 3cycles

- Recommendation

: Electra 219/189

- Test voltage

: Uo ± 144kV

- Recommendation

: Electra 219

- Test voltage

: - 1.85Uo, 8cycles

- Recommendation

: Electra 219

- Test voltage

: + 1.85Uo, 8cycles

- Recommendation

: Electra 219

- Test voltage : 1.85Uo / 2hr

Subsequent DC test

Type test process of 80kV/500MW

According to Electra TB-538, Electra 219 and Electra 189

Thermal contraction

measurement

- Movement by traction force

- According to company

regulation

29/Page

Load cycle test of DC 80 kV/500MW

24 hr load cycle test of polarity reversal

Starting Operation: Dec. 20, 2012

- No quench / No breakdown

48 hr load cycle test of positive pole

30/Page

Long term test

24 hr load cycle test of positive

Experienced 4th cool-down process


24 hr load cycle test of polarity reversal

Additional test

Voltage Test of DC 200kV class



Future Plan ► Development & Demonstration of Transmission Level

HTS Cable System




32/Page

Title: Development & Demonstration of Transmission level HTS Cable System

Period: July, 2011 ~ June, 2016 (60months)

Supervision: KEPCO

Participant: LS CNS, KERI & Several Universities

Research Funds: USD70M (Government: USD22M , KEPCO: USD18M, LS CNS: USD30M)

Summary

○ Development of SFCL

○ Performance Evaluation &

Installation in Grid

○ Development of the Method

for O&M

○ Development of HTS Cable

○ Installation & Operation in Grid

○ Localization of HTS Cable &

Cryogenic System

○ Finding the way of institutional support for commercialization

○ Selecting the site for demonstration

○ Review of Standard for product & test

Supervision (KEPCO]

○ Grid Analysis & Relevant effect

○ Grid Operation System

○ Verification of HTS Cable

Participant 1 (KEPRI) Participant 2 (LS CNS) Participant (KEPRI)

Composition & Aim of Project

33/Page

Overview of Pilot Application

E-mail : [email protected]

development and commercialization status of hts cable...

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