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 Demonstration of 22.9kV/150MVA HTS Cable System

Development of 80kV/500MW HTS Cable System Future Plan

’01

MEST1)

’02

’03

’04

’05

Developing

Developing

22.9kV /50MVA 30m (1-Φ)

22.9kV /50MVA 30m (3-Φ)

’06

’07

Carrying out Int’l Certification & Long-term Test

22.9kV/50MVA 100m

DAPAS3) Program

Demonstration in Actual Grid MKE2)

’08

’09

’10

’11

Progressed

’12

’13

’14

’15

’16

Demonstration in Actual Grid

154kV/1GVA 100m

Actual Grid (ICHEON S/S)

Actual Grid (ICHEON S/S)

22.9kV/50MVA 500m

22.9kV/150MVA 100m

Pilot Project

Basic R/D for

DC 200kV

Actual Grid (JEJU Island)

DC 80kV/500MW 500m Actual Grid (JEJU Island)

154kV/500MVA 1km Commercial Target

1)MEST:

Developing

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

200kV/5GW 3/Page

via National and In-house Projects

22.9kV

AC

▪ 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

80kV

DC

▪ 500MW 200kV ▪ 5GW

Completing Development in 2013

Completing Basic R/D in 2011 Planning Development and PQ test till 2016 4/Page

Contents Development of HTS Cable in Korea

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

Demonstration of 22.9kV/150MVA HTS Cable System Development of 80kV/500MW HTS Cable System

Future Plan

 Air view of HTS Cable System in Icheon S/S  Bending point: total 9 with 90° bending angle

4

2

5

3

1 1 2 3 4 5

22.9kV/50MVA HTS Cable Termination Joint Bay Cooling System Offset System 6/Page

 Overview of HTS Cable System in Icheon S/S  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 7/Page

HTS Cable  Specification  Characteristics - 22.9kV (Nominal), 13.2kV (Phase) - 1,260A (50MVA) - Short Circuit Rating: 25kA/30cycle (Cu Stabilizer) - Application of Cryogenic System (Open-loop type)  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 8/Page

Termination & Joint

 Termination

Pre-fabricated

 Compact Design  3-Φ in one cryostat (22.9kV)  Maximum Operating Pressure : 15bar

•Jointing at site

 Pre-fabricated components  Polymer composite Bushing

 Joint Bay  Compact Design (500mm Ø, 3.5m L)

 Insulation Level up to 35kV Grade  Coverable range: 13.2kV ~ 35kV  Pre-fabricated components  Maximum Operating Pressure: 15bar Pre-fabricated

9/Page

Cooling system  Overview  Open-loop type using Decompression unit  Capacity: 6.5kW @ 69K

Buffer for balancing System pressure and fault current 10/Page

Cooling system  Specification Item

Operating Condition

Specification

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

Cable & Termination

4,100W

Cooling System

800W

Cable & Termination

1.4bar

Cooling System

1.1bar

Heat Load

Difference of Pressure

11/Page

Cooling system  Photos of 22.9kV/50MVA Cooling System  Open-loop type - Decompression Unit  Heat exchanger in decompression cryostat  Vaporizer and decompression pump

12/Page

HTS Cable  Manufacturing Stranding of Former

Wrapping & Cushion Layer

Stranding of HTS & Conductor Screen

Electric Insulation & Insulation Screen

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

Stainless steel and carbon paper tapes shall be wound to bind the former according to the designed diameter

HTS wires and LPP papers shall be wound over the cushion layer, which will be controlled together using stranding machine modified for HTS cable

During the lapping of LPP papers, tension shall be carefully controlled for insulation quality and bending characteristic

MLI Taping

Outer Cryostat

Outer Jacket

After cleaning the surface of inner cryostat, MLI is wrapped and 4 Teflon spacers shall be stranded on the surface of MLI

The height and pitch of corrugated Al cryostat is critical to bending characteristic

During the extrusion, cable diameter is measured by X-ray scan

Inner Cryostat The height and pitch of corrugated Al cryostat is critical to bending characteristic

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℃

13/Page

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

Details - Long term test (load cycle test)

22.9kV 50MAVA HTS Cable 30m Proto type test (2005)

Result 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 14/Page

Control system  Evaluating Unmanned Operation System for Cooling System MS

HMI (Server PC)

Local Network

Input Control Value

HMI (Client PC)

User

Date Acquisition Ethernet Control Net

ProfiBus

PLC duplex configuration (watchdog, quick change when Failed)

LTS No.

JTS

REM PLC

STS Item

DUM PLC

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)

4

DUM(Decompression Unit Module)

5

Cryogenic Refrigerant

6

LTS(Load Termination System)

7

JBS(Joint Bay System)

8

STS(Source Termination System)

• 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.

• Explosion-proof type(IP 55) • Controlled by CS and Communication with CS. 15/Page

Control system  Action Plan According to Fault Level Level 3 2 1

Action Engineers standby within 24hrs Alarming for observation to decide cutting power or not Engineers standby within 5hrs & Clearing alarms after measures Stopping the operation: Cutting power

countermeasure Sending SMS to people in charge Informing to 2nd line of SCADA Sending SMS to people in charge Informing to 1st line of SCADA Sending SMS to people in charge

 Condition for Deciding Faults Step

Level

1

Deciding Faults

Breakdown Fulfilling conditions: Inner pressure of Reservoir & Load-side termination

2

Fire 1

Setup

Maintaining Time

Under 2barG

10sec.

Installing the fire alarm in Cooling room and Joint room Over 75K

10sec.

4

Explosion & Fulfilling conditions: Inlet temp. of cable (2 points), Joint (2 points) Damage of HTS wire Fulfilling conditions: Pressure of outlet of circulation pump & source-side termination

Over 6.5bar G

0.5sec.

5

Breakdown Fulfilling conditions: Inner pressure of Reservoir & Load-side termination

Under 2.5barG

10sec.

6

Explosion & Fulfilling conditions: Inlet & Outlet temp. of cable (4 points), Joint (2 points) Damage of HTS wire Fulfilling conditions: Pressure of outlet of circulation pump & Source-side termination Flow rates of LN2 Maintaining Fulfilling conditions: Vacuum condition of cable, joint & termination Cooling Fulfilling conditions: Inner pressure of pneumatic tank system Fulfilling conditions: Level of LN2 tank Whole Informing people in charge after checking malfunction or abnormality of all sensors system

Over 73K

20sec.

Over 6bar G

5sec.

Under 0.2kg/s

10sec.

Over 0.1torr

10sec.

Under 4.2bar

10sec.

Under 15%

10sec.

3

7 8

2

9 10 11

12

3

16/Page

 Test Specifications and Results 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

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

17/Page

 Trend of Load Current vs. Quantity of Heat Capacity  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

 1-day trend during Increasing Load Current to 600A

Aug. 19

Mar .31

 20 months trend from starting demonstration

18/Page

 Trend of vacuum  HTS cable length of 22.9kV/50MVA - 500m (Two span : Connection with joint bay)  Operation period - Total 20 months - Unmanned operation during18 months 1 Cable span 200m Cable span 300m

0.1

Vacuum [torr]

0.01 1E-3

 20 months trend from starting demonstration - Very stable the degree of vacuum - Under 6.0E-6 torr

1E-4 1E-5 1E-6 1E-7 1E-8 8-1-2011

12-1-2011

4-1-2012

8-1-2012

12-1-2012

4-1-2013

Date 19/Page

Development of HTS Cable in Korea Demonstration of 22.9kV/50MVA HTS Cable System Demonstration of 22.9kV/150MVA HTS Cable System ► Component ► Installation

Demonstration of 80kV/500MW HTS Cable System Future Plan

 Air view of HTS Cable System in Icheon S/S

4

1

2

3

1 2 3 4

22.9kV/150MVA HTS Cable Termination Cooling System in Container U-bending area 21/Page

 Overview of HTS Cable System in Icheon S/S  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

22/Page

HTS Cable  Specification  Characteristics - 22.9kV (Nominal), 13.2kV (Phase) - 3,750A (150MVA) - Short Circuit Rating: 25kA/30cycle (Cu Stabilizer) - Application of Cryogenic System (Hybrid type)  Design - Cold Dielectric - Outer Diameter: 159mm

- 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 23/Page

Cooling system  Overview  Hybrid type : Close loop + Open loop - Using 4kW Stirling refrigerator - Using decompression unit  Capacity: 10kW @ 69K PCS (Pressure Control System) Seperator

Filter Unit CP (Circulation Pump) Unit

DC (Decompression) Unit

24/Page

Development of HTS Cable in Korea Demonstration of 22.9kV/50MVA HTS Cable System Demonstration of 22.9kV/150MVA HTS Cable System

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

Future Plan 25/Page

 Photo of KEPCO power testing site in Gochang

2

E 1

3 E 1 2 3

80kV/500MW HTS Cable Outdoor Terminations Joint Bay Offset System

26/Page

HTS Cable  Specification  Characteristics - 80kV (Nominal) - 3,125A (500MVA) - Short Circuit Rating: 6.25kA/30cycle (Cu Stabilizer) - Application of Cryogenic System (Close-loop type)  Design - Cold Dielectric - Outer Diameter: 149mm

- Seamless Al Cryostat - PVC Sheath - Insulation Level up to DC 200kV : Coverable Range : DC 80 ~ 200kV - Fault Current By-pass with Stabilizer

27/Page

HTS Cable  Type test process of 80kV/500MW  According to Electra TB-538, Electra 219 and Electra 189 Jointing & Assembling Cryostat

Leak test

Vacuum exhausting & Assembling Bushing

- 1x10-8 mbar•ℓ/sec

Cool - down - According to company regulation

24hr Polarity reversal test - Recommendation : Electra 219 - Test voltage : ± 1.45Uo, 8cycles

Thermal contraction

measurement - Movement by traction force

48hr Positive Load cycle test - Recommendation : Electra 219 - Test voltage : 1.85Uo, 3cycles Warm-up

Pressure test - According to Cigre W/G B1-31

24hr Negative Load cycle test - Recommendation : Electra 219 - Test voltage : - 1.85Uo, 8cycles

S/I Switching Imp. test - Recommendation : Electra 219/189 - Test voltage : Uo ± 144kV Long term reliability test

24hr Positive Load cycle test - Recommendation : Electra 219 - Test voltage : + 1.85Uo, 8cycles

S/I Lightning Imp. test - Recommendation : Electra 219/189 - Test voltage : Uo ± 285kV

Special test Subsequent DC test - Recommendation : Electra 219 - Test voltage : 1.85Uo / 2hr

28/Page

 Load cycle test of DC 80 kV/500MW  Starting Operation: Dec. 20, 2012 - No quench / No breakdown

 24 hr load cycle test of polarity reversal

 48 hr load cycle test of positive pole 29/Page

 Long term test  Experienced 4th cool-down process - No quench / No breakdown

 Additional test  Voltage Test of DC 200kV class - No quench / No breakdown

 24 hr load cycle test of positive

 24 hr load cycle test of polarity reversal 30/Page

Development of HTS Cable in Korea

Demonstration of 22.9kV/50MVA HTS Cable System Demonstration of 22.9kV/150MVA HTS Cable System Development of 80kV/500MW HTS Cable System Future Plan ► Development & Demonstration of Transmission Level HTS Cable System

 Summary   

 

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)

 Composition & Aim of Project Supervision (KEPCO] ○ Finding the way of institutional support for commercialization ○ Selecting the site for demonstration ○ Review of Standard for product & test Participant 1 (KEPRI) ○ Grid Analysis & Relevant effect ○ Grid Operation System ○ Verification of HTS Cable

Participant 2 (LS CNS) ○ Development of HTS Cable ○ Installation & Operation in Grid ○ Localization of HTS Cable & Cryogenic System

Participant (KEPRI) ○ Development of SFCL ○ Performance Evaluation & Installation in Grid ○ Development of the Method for O&M 32/Page

 Overview of Pilot Application

33/Page

E-mail : [email protected]