Design, Test and Demonstration of Saturable- Core Reactor HTS Fault Current Limiter

1

Design, Test and Demonstration of Saturable-

Core Reactor HTS Fault Current Limiter

U.S. Department of Energy Annual Peer Review

Alexandria, VA

June 29 – July 1, 2010

Presenters:

Albert Nelson, Franco Moriconi, Robert Lombaerde

2

Presentation Outline

Program Overview and Team Description – Robert Lombaerde

FY 2010 Program Highlights – Robert Lombaerde

California Energy Commission/Southern California Edison FCL

Operational Experience – Franco Moriconi

Powertech Labs Testing Results – Franco Moriconi

AEP Transmission Class FCL Design – Albert Nelson

Magnet Design and Thermal Models – Robert Lombaerde

Summary of Accomplishments and FY 2011 Plans – Robert Lombaerde

3

DOE Program Overview

Intermediate Goal: Design, Build,

and Test Distribution-Class

Saturable Core Reactor FCL

End Goal: Design, Build, and Test

Transmission-Class Saturable

Core Reactor FCL

4

Project Partners

Zenergy Power Inc.

Designs and manufactures fault current limiters

Zenergy Power Pty Ltd

Invents and tests new FCL concepts

Zenergy Power GmbH

Manufactures all HTS components for Zenergy Power, expertise in coil

fabrication and cryogenic integration

AEP – American Electric Power

138 kV FCL Host

Los Alamos National Lab

Consulting Partner, Magnetic Modeling, Testing, Data Analysis

Oak Ridge National Lab

Consulting Partner, AC Loss Measurements of HTS conductors

5

HV FCL Project Overview

2007 2008 2009 2010 2011

DOE 13 kV compact device

CEC 13 kV So. Cal. Edison

ConEd

13kV Proto

ConEd

Study

AEP

138 kV Single Phase

AEP

138 kV 3 Phase

CE Electric

11 kV 3 Phase

2012

6

12 kV Commercial Sale

Applied Superconductor Ltd for CE Electric, UK

Requirements Summary

• 12 kV

• 1250 Arms

• 17 kApeak prospective fault

• Reduce fault by 30%

• Recovery under load required

• Fault duration up to 3 seconds

• Install in late 2010

7

From 2009 Peer Review

Plans for FY 2010

Gain operational experience with 12kV device installed at SCE‟s Avanti

Circuit of the Future. Completed

Finalize host utility for 138kV demonstration device. Completed

Finalize design of 138kV device based on host utility input. CY-2010

Start construction of first phase of three-phase FCL. CY-2010

8

Landmark Installation: Los Angeles, March 2009

115 kV LINE

115/12kV

Transformer

BYPASS

SWITCH

Operational Experience – 12 kV AVANTI “Circuit of the Future”

First installation in U.S. electricity grid

Operated by Southern California Edison

Installed in Avanti “Circuit of the Future”

First Energized on March 9, 2009

Supported by DOE and California Energy Commission

9

sub12kV

PLOTS

P_Source P_Source

Q_Source Q_Source

V_Source V_Source

431'

1000XLP

PI

COUPLED

SECTION

VFI1544

591'

1000XLP

PI

COUPLED

SECTION

GS_1545

6,415'

1000XLP

P = 5.533Q = -0.3882V = 1.044

V

A

Shandin

L_CB1

L_CB1

#1#2

#3

L_CB4

L_CB4

L_CB3

L_CB3

TimedBreakerLogic

Closed@t0

TimedBreakerLogic

Closed@t0

TimedBreakerLogic

Closed@t0

SHANDIN

115-12 kV

P = 5.535Q = -0.3298

V = 120V A

RLV

FPh

RRL

0.001 [uF

]

0.001 [uF

] 0.001 [uF

]#1#2

#3

#1#2

#3

Avanti

12 kV, 1200A

FCL

Line Load

Ifa2 Ifa2

Ifb2 Ifb2

Ifc2 Ifc2

Vs

Freq

Phase

ZP Plots_PHASE_ALL

Tested @ Grid Voltage = 120 kV with reduced circuitModified Fault ON RESISTANCE = 0.01 OHM

Main ...

90

-90

MW-ph2_0

0

deg

60.0

MW-ph2_0

MW-V2_0

Main ...

120

115

MW-V2_0

120

kV

ABC->G

TimedFaultLogic

fault

fault

fault

Main ...

fault

0

O C

SW

SW

SW

Main ...

SW

0

O C

RMSIfa2_RMS

Ifa2_RMS

RMSIfc2_RMS

Ifc2_RMS

RMSIfc2_RMS

Ifb2_RMS

Ia4 Ia4

Ib4 Ib4

Ic4 Ic4

RMSIa4_RMS

Ia4_RMS

RMSIc4_RMS

Ic4_RMS

RMSIb4_RMS

Ib4_RMS

GS1536

RCS1088

PMH_43311.2 [MVAR]

CAPSW

1.279 [MVAR]-0.006076 [MW]

CAPSW

sw4

sw4

P = 3.018Q = -1.703V = 1.033

V

A

P = 1.583Q = -1.138V = 1.032

V

A

P = 0.3502Q = 0.1735V = 1.037

V

A

2,031'

1000XLP

GS1547

P = 0.3217Q = 0.1602V = 1.033

V

A

2,072'

1000XLP

100'

1000XLP

1,324'

1000XLP

Main ...

CAPSW

0

C O

P = 0.3209Q = 0.16V = 1.032

V

Abus1007

LOAD2

0.32 [MW] 0.16 [MVAR]

0.3 [MW] 0.15 [MVAR]

P = 5.137Q = -0.6407V = 1.037

V

A

P = 3.822Q = -1.303V = 1.033

V

A

P = 3.5Q = -1.463V = 1.033

V

A

PI

COUPLED

SECTIONPI

COUPLED

SECTION

OS1478

6,415'

1000XLP

PI

COUPLED

SECTION

GS1546

3,638'

1000XLP

PI

COUPLED

SECTION

GS4269

P = 4.786Q = -0.8141V = 1.037

V

A

5,160'

1000XLP

PI

COUPLED

SECTIONPI

COUPLED

SECTION

RCI_1449

PI

COUPLED

SECTION

900'

1000XLP

P = 0.7825Q = 0.3896V = 1.032

V

A

PI

COUPLED

SECTION

1,448'

1000XLP

PME2349

P = 0.3911Q = 0.1946V = 1.032

V

A

PI

COUPLED

SECTION

1,109'

1000XLP

J988

1,808'

750XLP

PICO

UPLED

SECT

ION

PI

COUPLED

SECTION

Main ...

sw4

0

C O

RCI_1453P = 1.582Q = -1.138V = 1.032

V

A

100'

1000XLP

PI

COUPLED

SECTION

RCS_1365

200'

1000XLP

PI

COUPLED

SECTION

BS1389

1.8 [MVAR]

CAPSW2

1.918 [MVAR]-0.009091 [MW]

CAPSW2

Main ...

CAPSW2

0

C O

100'350 XLP PI

COUPLED

SECTION

PS2062

645'

336 ACSR-Multigrounded

336 ACSR

P = 0Q = 0V = 0

V

A

0.32 [MW] 0.16 [MVAR]

P = 0.3536Q = 0.1748V = 1.039

V

A

0.32 [MW] 0.16 [MVAR]

P = 0.3459Q = 0.1719V = 1.034

V

A

0.32 [MW] 0.16 [MVAR]

P = 0.5918Q = 0.2891V = 1.033

V

A

0.55 [MW] 0.27[MVAR]

P = 0.3217Q = 0.1602V = 1.033

V

A

0.30 [MW] 0.15 [MVAR]

P = 0.3213Q = 0.1601V = 1.032

V

A

0.30 [MW] 0.15 [MVAR]

0.30 [MW] 0.15 [MVAR]

P = 0.3913Q = 0.1951V = 1.032

V

A

0.366 [MW]0.183 [MVAR]

P = 0.3911Q = 0.195V = 1.032

V

A

0.366 [MW]0.183 [MVAR]

P = 0.3912Q = 0.1951V = 1.032

V

A

0.366 [MW]0.183 [MVAR]

P = 0.3955Q = 0.1951V = 1.032

V

A

0.37 [MW] 0.183 [MVAR]

P = 1.583Q = -1.138V = 1.032

V

A

P = 0.4047Q = -1.723V = 1.032

V

A

P = 0.7865Q = 0.3891V = 1.032

V

A

E4201965

548'

1000XLP

PI

COUPLED

SECTION

P = 0.1608Q = 0.0801V = 1.033

V

A

0.15 [MW] 0.075 [MVAR]

FCL

Feeder application

AVANTI

CIRCUIT

of the FUTURE

Line Voltage 12 kV, 60Hz

Load Current 800 A max

Voltage Drop < 70 Vrms

Fault Current 23 kArms

X/R 21.6

Fault duration 30 cycles

Limit first-peak by at least 20%

Limit 3-phase to ground fault

Recover automatically

Mechanically robust

Fail safe operation

Operational Experience – 12 kV AVANTI “Circuit of the Future”

SATURABLE IRON CORE FCL - OPERATING PRINCIPLE

Picture-Frame Iron-Cores

AC CoilAC Coil

Boost Buck

Configuration for

single phase FCL

Inductive Fault Current Limiter

The equivalent FCL inductance is a non-linear function of the instantaneous line current,

and it may look like the graph below during a fault:

CLR

Constant

Inductance

-15.0 -10.0 -5.0 0.0 5.0 10.0 15.0 -0.0010

0.0000

0.0010

0.0020

0.0030

0.0040

0.0050

0.0060 +y

-y

-x +x

X Coordinate Y Coordinate

I_Limited L_cus

Equivalent Inductance

Instantaneous AC Current [kA]

FCL Inductance

is small at load current

FCL Inductance

Increases dramatically

during a fault

FCL CHARACTERISTIC CURVE

6X1 FAULT CURRENT LIMITING CAPABILITY

0

0.4

0.8

1.2

1.6

2

2.4

2.8

3.2

3.6

4

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Limited Current [kA]

FC

L b

ack e

mf

[kV

]

1

2

3

4

5

FC

L G

ain

- K

FC

L

6x1 Measured 120A DC 1% Insertion impedance FCL Gain

CLR

FCL

BACK

EMF

IMPEDANCE

GAIN

13

SUMMARY of Operational Experience

•18 months of operation

•Operating in a harsh environment

•Maximum ambient temperature reached was 108°F in Summer „09

•Heavy winds and dusty area

•Experienced one loss of DC with consequent “resonance” condition (IEEE paper)

•Successful integration with automatic bypass switch

•Experienced one fault event with multiple faults in quick succession (14 January „10)

•Experienced three “auxiliary power failures”

• Effective bypass of FCL and shut-down of the HTS coil (as expected)

• “Auxiliary power failures” caused by grid disturbances

• Instantaneous bypassing achieved by SCE (2 out of three)

• Successful recovery after 2-minute black out of auxiliary power

•Performed routine maintenance on cryogenics compressors

• Replaced cryo-compressor after 8000 hours

• Replenished LN2 after HVAC loss (hot Summer 2009)

Siemens PLC Network

Features:

- SMS Warning Text Messages

- SCADA Control via Wonderware

- Data Archiving via Wonderware

- Modbus Interface for SCE

Siemens PLC

3G GSM

Data ModemWonderware

ServersW.W.W. ZP PC

Cell

Tower

GSM Text Modem

Modbus Interface

Text Message

SCE

SCADA

Separate Ethernet Port

FCL

Fault Event - Summary of operating experience AVANTI FCL

three seconds

one second3.5 KA peak

0.2 KA load


AC FAULT

NO EFFECT on DC


NO EFFECT on CRYO


NO EFFECT on CRYO

Loss of Auxiliary Power - Summary of operating experience

Sunday June 27 2010, 1:30AM – Substation power outage lasting over 2 minutes

2 minutes

Line Voltage 7 kVrms

DC MAGNET SHUTDOWNDC BIAS CURRENT 100 A

Loss of Auxiliary Power - Summary of operating experience

Sunday June 27 2010, 1:30AM – Loss of substation power for over 2 minutes

2-minute

interruption

Nitrogen Vapor Pressure

LN2 Temperature

Cryo-compressor recovery

Cold Head Temperature

21

Zenergy Power – ’09-’10 Results Summary

Installation of 12 kV FCL in Southern California Edison‟s Circuit of

the Future.

First successful integration superconducting FCL in US grid

Operational experience at SCE has been a big success for

both Zenergy and SCE

Resonance study revealed minimal effects

Both parties gained invaluable experience by operating

through all four seasons

Zenergy learned to address unplanned events such as loss

of station power

The host utility learned about preventive maintenance and

how the device responded to real fault event

Similarity of Compact FCL Design to Picture Frame Design

AC input AC output

Picture frame single phase Compact single phase

HTS

coil

Proprietary [22]

2x13x2

6x1

Full-Scale Compact Modules Tested in 2009

24

SHORT CIRCUIT TEST RESULTS – POWERTECH July 2009

32% FAULT CURRENT REDUCTION of a 15kArms PROSPECTIVE

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5-30

-20

-10

0

10

20

30

40

COMPACT FCL - 15kArms PROSPECTIVE FAULT LIMITED TO 10.7kArms - 32% REDUCTION

CU

RR

EN

T [

kA

]

V

OLT

AG

E in

Blu

e [

kV

]

TIME [sec]

anim97.avi

25

SHORT CIRCUIT TEST RESULTS – POWERTECH July 2009

46% FAULT CURRENT REDUCTION of a 25kArms PROSPECTIVE

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1-40

-30

-20

-10

0

10

20

30

40

25kArms PROSPECTIVE FAULT LIMITED TO 13.5kArms - 46% REDUCTION

CU

RR

EN

T [

kA

]

TIME [sec]* FCL Terminal Voltage in Blue

anim100.avi

THE PATH TO COMMERCIALIZATION

SPIDER

2.5x2.5 m footprint

Effective core 300 cm2

Rectangular COMPACT

2.0x1.3 m footprint


Prototype AC coils and magnets

ROUND COMPACT

1.8m OD footprint


Commercial product

FROM

DEMONSTRATORTO

PROTOTYPE

TO

PRODUCT

COMPACT FCL – COMMERCIAL INSTALLATION December 2010

15 kV Voltage Rating

3-Phase, 50 Hz

1.25 kA Nominal Current

28

AEP Tidd Substation Requirements

Requirements Summary

• 138 kV

• 1300 Arms

• ~ 20 kArms prospective fault

• Reduce fault by 43%

• Recovery under load required

• Fault test single-phase early 2011

• Install 3-phase device late 2011

29

AEP Tidd Substation, Brilliant, Ohio

Proposed 138 kV FCL Location

345 kV to 138 kV Transformer138 kV Feeder

30

Rapid Prototyping and Resulting Design Change

BLUF (bottom line upfront) AEP design changed from 1x2 configuration to

2x1 configuration after extensive prototyping and testing following Readiness

Review Team (RRT) meeting

AEP initial design (1x2) completed in December 2009

RRT (January 2010) proposed additional investigations to reduce technical

risk

Large (about ½ scale) device built and tested at Lane Cove, Australia

Extensive modeling in advance of testing

Modeling focused on areas of uncertainty

Exhaustive testing completed (100‟s of tests)

31

1 x 2 Round Core Test

32

Actual 1 x 2 Test Device

33

Lane Cove Testing Results

Measured results confirmed predictions

50%

34

Arcing Due to High Induced Voltage

But not everything worked as expected

35

Design Evaluation Leading to Change

Test results from Lane Cove clearly demonstrated that:

Proposed 1x2 device was not optimal

While feasible, it would not be implemented easily

Design was inherently unbalanced electromagnetically

Displayed large mechanical forces, high variable AC flux outside

device envelope, pronounced shielding effect, and high induced

voltages

36


1x2 design chosen originally for perceived manufacturing ease

Round cores with round coils on round formers in round tanks

“New” 2x1design places ½ electrical phases alongside each other

Previously tested at Powertech in July 2009

Test results suggested design should be more balanced

Shielding and induced voltage effects minimized

Modeling predicts improved performance

½ phases side-by-side cancel each other‟s effects

AC flux variations outside of device envelope reduced significantly

37

2x1

Full-Scale Compact Modules Tested in 2009


3x26x1

38


1x2 design chosen originally for perceived manufacturing ease

Round cores with round coils on round formers in round tanks

“New” 2x1design places ½ electrical phases alongside each other

Previously tested at Powertech in July 2009

Test results suggested design should be more balanced

Shielding and induced voltage effects minimized

Modeling predicts improved performance

½ phases side-by-side cancel each other‟s effects

AC flux variations outside of device envelope reduced significantly

39


2x1 FCL design chosen as new baseline

Large-scale prototype to be tested at Lane Cove in July 2010

High-voltage (138 kV L-G) single-phase under construction

AC “test tank” to be built using production device techniques

Designed to use HTS magnets from another project (ASL 11 kV)

Slightly sub-scale (ASL is 3θ at 11 kV versus 1θ at 138 kV)

Testing at KEMA in Chalfont, PA in November 2010

Preliminary 2x1 design has been completed

Electrostatics are compatible with largest Zenergy production magnet

Device performance consistent with RRT recommendation

40







Slightly sub-scale (ASL is 3θ at 11 kV versus 1θ at 138 kV)





41

Single-Phase Lane Cove FCL Demonstrator

42


Confidential and Proprietary Information






Approximately full-scale (ASL is 3θ at 11 kV versus 1θ at 138 kV)





43







Approximately full-scale (ASL is 3θ at 11 kV versus 1θ at 138 kV)





44

AEP 2 x 1 FCL Predicted Performance

AEP Tidd Substation 3-Phase FCL

45

AEP 2x1 FCL Predicted Performance

AEP Tidd Substation 3-Phase FCL

46

Summary Schedule January – December 2010

J F M A M J J A S O N D

RRT Meeting

1x2 Prototype Testing

RRT Review

2x1 Prototype Testing

RRT Review

2x1 HV HTS Prototype Testing

RRT Review

Finalize Design

2010

Achievements

47

Importance of AC Losses

Fringing ac fields generate losses

in HTS dc coil

Losses must be characterized and

accommodated in thermal design

Estimates range from 10‟s to

100‟s of watts per coil

Need measurements instead of

calculations

Losses concentrated on coil

edge; not uniformly distributed

Stray ac field profiles in the dc coil

48

Voltage arrangement used to measure dynamic resistance in HTS samples

Liquid

nitrogen

dewar

DC

background

LTS magnet

AMI ac

magnet

Sample

location

ORNL Experimental Resources

Characterization of 1G and 2G wires

carried out in the following conditions

AC field (0-20 mT)

DC field (0 – 2 T)

Parallel / Perpendicular field orientations

DC current (0-100% Ic)

77 K initially, then 30 K

S-shaped voltage

taps

Idc

Bdc Bac

HTS sample

49

Losses Depend Upon Iop / Ic

0.E+00

1.E-05

2.E-05

3.E-05

4.E-05

5.E-05

6.E-05

7.E-05

0 5 10 15 20 25

Peak perpendicular field [mT]

Res

ista

nce

[ohm

s/m

]

0.5 Ic

0.6 Ic

0.7 Ic

0.8 Ic

0.9 Ic

Dynamic resistance as a function of peak perpendicular field at different percentages of

dc current to the sample dc critical current (no external dc field)

Losses increase as Iop / Ic increases

Zenergy will optimize for wire cost vs. cryogenics cost

3x increase

in ac losses

50

Dynamic Resistance Measurements at

30 K to 50 K are Important

Using 77 K data, loss from dynamic

resistance is between 0.1 mW/m to 15

mW/m.

Operation of HTS coil at 30 to 50 K will

increase critical current, which will

increase the threshold current

Preliminary measurements on a 1G

wire have been done at 77 K on cryo-

cooled system and have confirmed this

observation

Custom equipment developed by

ORNL

51

Risk Mitigation of HTS Coils

Goal: Validate thermal design

Half-scale (0.7 m) copper coil

constructed

“Dry” cooling thermal design

Resistive heaters installed at coil edge

to simulate AC losses, DC connections

Novel copper cold bus implemented

Tested in cryostat with production

cold-head

Heat transfer models developed for

correlation

52

Copper Coil Integration in Test Cryostat

Coldhead

Superinsulated

copper coil in

cryostat

53

FE Simulation vs. Measurements

Cool down to thermal steady-state at 17 K

17 K

54

Plans for FY 2011

Decommission the12 kV FCL installed at SCE‟s Avanti Circuit of the

Future and perform post-mortem.

Finalize design of 138 kV device based on host utility input and test

results.

Build and test 138 kV single-phase FCL.

Start construction of second and third 138 kV electrical phases.

Start qualification of 2G Wire for FCL DC Coils.

55

DOE – AEP Schedule

AEP - Tidd Schedule

J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D

Build 2x1, Test LC, AU

Test 2x1 at KEMA, PA

Review Test Results

Build AEP FCL

Test AEP 2x1 First Phase

Assemble Phases 2 & 3

Install AEP 3-Phase FCL

Tidd Configuration Design

Tidd Configuration Final

Tidd Construction

Monitor and Maintain FCL

2010 2011 2012

56

Zenergy Power - 2010 Results Summary

Successful operational experience with 12 kV FCL in Southern

California Edison‟s Circuit of the Future.

AEP is host utility for the 138 kV FCL – Target specifications

verified and accepted.

Rapid FCL prototyping enabled 138 kV designs to progress;

expect design lock in December.

Rapid HTS magnet prototyping enabled thermal design to be

locked. Long-lead materials on order; expect magnet

construction in December.

57

Cooperative Entities

Southern California Edison – Participant in Circuit of the Future through

contract with California Energy Commission.

American Electric Power – Participant as host utility for 138 kV

demonstration Project.

Consolidated Edison – Participated in study of Compact FCL and

participates in regular program updates.

LANL – Contributed in the areas of magnetic modeling, testing and data

analysis.

ORNL – Contributed in the area of AC loss measurements of different

conductors.

NEETRAC – Zenergy is a member of organization providing guidance to

steer FCL performance and testing requirements.

CIGRE Working Group A3.23-Fault Current Limiters – member of

working group.

IEEE Working Group on Testing of Fault Current Limiters – member

of task force.

58

Thank You

Date post:	14-Jun-2015
Category:	Technology
Upload:	franco-moriconi
View:	664 times
Download:	3 times

Design, Test and Demonstration of Saturable- Core Reactor HTS Fault Current Limiter

Technology