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EPRI 2011 Nexans SuperConductors
Mathias Noe
Karlsruher Institut für Technologie
&
Joachim Bock, Achim Hobl, Judith Schramm
Nexans SuperConductors GmbH
Tenth EPRI Superconductivity Conference
October 11-13, 2011
Superconducting Fault Current Limiters
Latest developments at Nexans SuperConductors
EPRI 2011 Nexans SuperConductors
• Introduction
• SFCL systems– Function
– Operation behaviour
– Commercial Projects• ASL I 12-100
• ASL II 12-400
• Vattenfall 12-800
– Development Projects• ENSYSTROB
• ECCOFLOW
– Latest Project: AmpaCity
• Conclusions
Outline
EPRI 2011 Nexans SuperConductors
Chemiepark Knapsack
10 km South-west of Köln
Chemiepark Knapsack
in Hürth
EPRI 2011 Nexans SuperConductors
• Assembly of Fault Current Limiter systems
• Building height allowing crane hook of 7 m
• Optimisation of the production
Office building and
assembly hall
bldg. 2728
Nexans SuperConductors
in new premises 2010
EPRI 2011 Nexans SuperConductors
buffer
2buffer
1substrate
YBa2Cu3O7-x
Bi-2212/ Bi-2223 tape
1st generation
Bi-2212 bulk
Y-123 cc-tape
2nd generation
Y-123 bulk
Materials and conductor types
for industrial HTS applications
Systems
realized
EPRI 2011 Nexans SuperConductors
Metal oxides
Melting
CastingAnnealing
BSCCO-2212
Melt Cast Processing
Production of HTS-bulk
Highly efficient and
very flexible process
Mixing
EPRI 2011 Nexans SuperConductors
normal operation short-circuit recovery
time
curr
ent
w/o FCL
îr
îmax
îp
td trta
Operating behaviour
of the FCL
• ultrafast
reacts in 1-2 milliseconds
• automatic
no external trigger necessary,
self-recovering
• wear-free
service only for cooling
system
Superconductor Fault Current Limiters are intrinsically safe!
EPRI 2011 Nexans SuperConductors
12-100 (ASL 1)
first commercial systemField tested for ~8 months
12-800 (Vattenfall)
first system in a power stationField tested Nov. 2009- Dec. 2010
FCL systems
Commercial Projects
XX-YYY
XX: Voltage [kV]
YYY: Current [A]
12-400 (ASL 2)
second system for UK (bifilar)Presently under installation
EPRI 2011 Nexans SuperConductors
• first FCL-System realised by NSC
• first commercial system worldwide
ASL I 12-100
Realisation
EPRI 2011 Nexans SuperConductors
ASL, Newcastle
ENW, Bamber Bridge
Live on grid
10-2009 to 06-2010
ASL I 12-100
Field test
EPRI 2011 Nexans SuperConductors
ASL II 12-400
Testing
Test at IPH
Customer has ordered second system!
EPRI 2011 Nexans SuperConductors
ASL II 12-400
Installation site
Ainsworth Lane
(Scottish Power)
In UK around 270 substations (MV up to 33 kV)
are at or above max. rating
EPRI 2011 Nexans SuperConductors
Block Q in Boxberg
Vattenfall 12-800
Brown Coal Power Plant
EPRI 2011 Nexans SuperConductors
Power to the consumer
EPRI 2011 Nexans SuperConductors
Power to the consumer
Auxiliary Power
EPRI 2011 Nexans SuperConductors
Not limited short circuit currents
Auxiliary Power
EPRI 2011 Nexans SuperConductors
High Short Circuit Currents
high mechanical and thermal forces
No “fuses” on the MV power distribution level
equipment and grid must be short-circuit proof
high investment for equipment “oversizing”
800
fault
63.000
rating
Investment
Cu
rren
t [
A]
Auxiliary Power
EPRI 2011 Nexans SuperConductors
Location
in Boxberg power plant
EPRI 2011 Nexans SuperConductors
• Installation
10/ 2009
• Commissioning
02.11.2009
• End of field-test
12/ 2010
• Significant savings for extension and new construction
• Improved safety for personnel and equipment
First FCL worldwide
in a power plant
• second field-test
starts IV/ 2011
EPRI 2011 Nexans SuperConductors
BSCCO-2212
tubes
BiSrCaCuO
powder
Fault Current Limiter
Components
Melt Cast Process
Nexans proprietary process
From metal oxide powder
to HTS-components
EPRI 2011 Nexans SuperConductors
component module set-up
of a phase
accomodation
in a cryostat
Basic design
of the FCL
•Fault Current Limiter connected in series with the grid
•Current and voltage adjustable by modular construction
Connection for adaptation
•Current in parallel
•Voltage in series
EPRI 2011 Nexans SuperConductors
Realisation
of the FCL
Nexans is mastering
the full chain.
EPRI 2011 Nexans SuperConductors
High voltage and high current
testing of complete FCL-system
Testing scheme
• 75 kV lighting impulse
• 28 kV withstand voltage (1 min)
Testing scheme
• 63 kA (peak) maximum
• 3-phase full loads (4 shots)
EPRI 2011 Nexans SuperConductors
New developments:
FCL systems based on cc-tape
12-600 (ENSYSTROB)
first MV system with cc-tapeThis project has received funding
from German government under grant 03KP102A
EPRI 2011 Nexans SuperConductors
ENSYSTROB
voltage 12 kV
normal operating current 800 Arms
inrush current (50 ms) 4100 Ap
inrush current (15 s) 1800 Arms
prospective current 60 kA
first peak limitation < 30 kAp
limitation time 120 ms
limitation after 100ms 6.6 - 7 kA
• High inrush currents
• Small window for limited current
Specification
New developments:
ENSYSTROB
EPRI 2011 Nexans SuperConductors
2 twins in, 2 twins out
sc-length: 8 x 4.30
Central contact
U = 433 Vrms
I = 850 Arms
P = 360 kW
I
New developments:
ENSYSTROB - component
EPRI 2011 Nexans SuperConductors
inrush currents
1367 Ap / 50 ms 600 Arms / 15 s
New developments:
ENSYSTROB – characterisation (1)
EPRI 2011 Nexans SuperConductors
partial load
I prosp = 2 kAp
Erms = 0.05 V/ m
full load
I prosp = 32 kAp
Erms = 50 V/ m
short circuits
New developments:
ENSYSTROB – characterisation (2)
EPRI 2011 Nexans SuperConductors
3 x 32 =96
components
New developments:
ENSYSTROB – system integration
EPRI 2011 Nexans SuperConductors
3-Phase short circuit, Iprosp= 63 kA
New developments:
ENSYSTROB – Testing at IPH Berlin
EPRI 2011 Nexans SuperConductors
New developments:
ENSYSTROB – Next steps
• First system based on cc-tapes was engineered and
built in time
• SFCL device was successfully tested at the certified
high power test lab in Berlin in September 2011
• SFCL has been installed at the Boxberg power plant
• SFCL will go life to the grid in October 2011
EPRI 2011 Nexans SuperConductors
Kosice
Barcelona
Siegen
Mailand
Stockholm
Nexans and 13 European partners have reached a
EU-project: ECCOFLOW cc-tape based FCL 24-1000
•15 partners involved
• 5 utilities
• coordinated by
First multipurpose system
for two sites and applications
EPRI 2011 Nexans SuperConductors
ECCOFLOW is:
• A project to prepare
commercialisation of SFCL
• The 3-phase resistive limiter with
the highest voltage today
• Including 15 project partners
5 of which are utilities
• The first SFCL foreseen for two
different applications
New developments:
ECCOFLOW
EPRI 2011 Nexans SuperConductors
Palma de Mallorca
FCL
FC
L
busbar coupler
High voltage
Medium voltage
transformer
feeder
New developments:
Project 24-1000 ECCOFLOW
1st site for installation
San Juan de Dios
EPRI 2011 Nexans SuperConductors
Košice (VSE)
VSE grid
Košice, Slovakia
2nd site for installation
FCL
FC
L
busbar coupler
High voltage
Medium voltage
transformer
feeder
New developments:
Project 24-1000 ECCOFLOW
EPRI 2011 Nexans SuperConductors
Endesa VSE Eccoflow
Nominal voltage 16.5 kV 24 kV 24 kV
Nominal current 1000 A 1005 A 1005 A
AC withstand voltage 50 kV 50 kV 50 kV
Lightning impulse 125 kV 125 kV 125 kV
Max. prospective current (peak) 22 kA 26 kA 26 kA
Max. limited current (peak) 10.8 kA 17 kA 10.8 kA
Fault duration 1 s 120 ms 1 s
HTS limitation time 80 ms 80 ms 80 ms
Recovery time < 30 s < 30 s < 30 s
New developments:
Project 24-1000 ECCOFLOW
EPRI 2011 Nexans SuperConductors
Module of
components inside
cryostat
System with
parallel impedance
and circuit breaker
limitation
time > 120 ms
inrush currents
> 1.2 kA
„Black Box“
Air Core
Reactor
FCLCircuit
Breaker
FCLFCL
New developments:
Project 24-1000 ECCOFLOW
EPRI 2011 Nexans SuperConductors
Component Design
• 3 x 2 x 2 conductors, about 8 m each
• 1 kArms / 800 Vrms
• no parallel connection of components
needed
• excellent use of volume
• low voltage for the single component
• small AC losses due to multifilar
geometry
• short single pieces of superconducting
tape with mutual protection.
New developments:
Project 24-1000 ECCOFLOW
EPRI 2011 Nexans SuperConductors
Module Design
• Stack of 12 components in
series
• Liquid / gaseous nitrogen
insulating against cryostat
wall
New developments:
Project 24-1000 ECCOFLOW
EPRI 2011 Nexans SuperConductors
Cryostat Design
• 3 nitrogen vessels
• One common
vacuum vessel
• Boiling nitrogen at
77 K
• About 100 W
thermal losses
• G-M cryocooler
• Compact design
• Design close to
series production
New developments:
Project 24-1000 ECCOFLOW
EPRI 2011 Nexans SuperConductors
Loss contribution Loss at 0.1 Ic Loss at 0.5 Ic Loss at 1 Ic
Max. superconductor AC loss < 1 W ~ 10 W 150 W
Max. current lead loss 180 W ~ 220 W 270 W
Cryostat loss 120 W 120 W 120 W
Max. additional loss 1 W 15 W 60 W
Max. total loss at 77 K ~ 300 W ~ 365 W 600 W
Max. electric power at RT ~ 6990 W 8504 W 13980 W
Cryostat Design
• 3 nitrogen vessels
• One common vacuum vessel
New developments:
Project 24-1000 ECCOFLOW
EPRI 2011 Nexans SuperConductors
110-kV-substation
(suburban area)
10-kV-substation
(city center)
40 MVA
Conventional
110-kV-Cable
110-kV-substation
(suburban area)
10-kV-substation
(city center)
40 MVA
Latest Project
AmpaCity
10-kV-HTS cable
Supply of city center by MV HTS cable
EPRI 2011 Nexans SuperConductors
Study showed project is
• technically feasible
• economically reasonable
Kick-off Oct. 2011
AmpaCity
Feasibility Study
EPRI 2011 Nexans SuperConductors
Dellbrügge
Herkules
position of joints
AmpaCity
in the City of Essen
EPRI 2011 Nexans SuperConductors
AmpaCity
HTS cable with stand alone FCL
EPRI 2011 Nexans SuperConductors
• Full chain mastered from production of HTS material to
final FCL system (for bulk)
• First commercial FCL systems realized
(w/o any public funding)
• Successful grid operations also with the first HTS
system in a power station worldwide
• Market entry with bulk already achieved
• New development projects started
first system realised based on cc-tape
multipurpose device
new solutions for urban areas
Conclusions
EPRI 2011 Nexans SuperConductors
First FCL worldwide
in a power plant
Thank you
for listening!