HTS Transformer De elopment Development

Bill Schwenterly S h t l Oak Ridge National Laboratory Ed Pleva Waukesha Electric Systems
June 30, 2010 Presentation for DOE Peer Review

Team: ORNL Bill Schwenterly, ORNLS h t l Jonathan J th Demko, D k Alvin Al i Ellis, Elli Robert Duckworth, Randy James, Isidor Sauers, Enis Tuncer WES- Ed Pleva, Sam Mehta, Vinay Mehrotra, Bob Del Vecchio

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Project Purpose
To establish the technical and economic benefits of
HTS Transformers of >10-MVA ratings.

To carry out materials studies in support of this

development. p

Supports DOE-OE Mission and Subprogram goals:

Modernize electric grid; Smart Grid Program. Enhance security, reliability and efficiency of energy

infrastructure. Develop revolutionary power equipment using HTS wires.

Characterize dielectric materials and establish design rules. Reduce cost of HTS equipment. equipment
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Program History
Ph Phase 1: 1 1994 2000 (WES (WES, IGC IGC, ORNL and d RG&E) 1 MVA 1- prototype tested 1998 13.8kV HV/6.9kV LV; Bi-2212; 25 K HV, vacuum, ac loss testing, cold mass assy at ORNL HV b breakdown kd caused db by MLI; MLI later reached 13.8 kV in air 5/10 MVA 3- prototype tested 2003-4 24 9kV HV/4 24.9kV HV/4.16kV 16kV LV; Bi-2223; Bi 2223; 25 K HV, ac loss testing, cooling system design/fab at ORNL Transformer failed HV dielectric tests; cracked epoxy insulation; root cause & lessons learned analysis done WES using internal funds; DOE base program funding to ORNL Conceptual design rework; 70-K YBCO; HV cryogenic i dielectric di l t i & ac loss l testing, t ti composite dewar development at ORNL Simplify manufacturing process Construct 28-MVA FCL Smart Grid Demo Transformer for SCE
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Phase 2: 2000 2005 (WES, SuperPower, ORNL and Energy East)

Ph Phase 3 3: 2005 Present P t (WES (WES, ORNL)

Phase 4: Future (WES, SP, SCE, ORNL)

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Why HTS Transformers?

HTS transformer development is underway worldwide.
Projects in Japan, Korea, China, India, Australia.

Many transformers in the grid are aging, creating a ready HTS market. HTS transformers can save energy and reduce CO2 emissions. emissions
Conventional transformer losses are 40% of total grid loss because they are so numerous y 1/3 If HTS transformer is 0.2% more efficient, losses are reduced by ~ 107 ton annual CO2 reduction

Transformer size, weight, fire hazard, and environmental impact reduced. Overload operation is possible with no loss of lifetime. Fault current limiting (FCL) capability is possible supports Smart Grid.
THIS IS UNDER DEVELOPMENT IN A NEW COLLABORATION WITH SUPERPOWER AND SOUTHERN CALIFORNIA EDISON.

FCL transformer development helps other FCL projects

High-voltage insulation, dewar development Conductor cooling, YBCO properties

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Fault Limiting Equipment is Enabler of Smart Grid

Fault currents are growing inexorably in expanding urban grids Need fast limiting of fault currents
avoid damage to grid and equipment avoid power interruptions

Without limiter With HTS limiter

Smart Grid vision of re-configurable networks requires connectivity

Fault current limiting q p equipment

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OUTLINE
Research plan Summary of new 28-MVA FCL Smart Grid
p j Transformer project
Specifications Overall configuration Winding g details Ed Pleva

Composite dewar long-term testing AC Loss testing and calculation High voltage insulation
550-kV BIL flashover test coil Bushing tests Bill Schwenterly

Goals vs Accomplishments Technology Transfer/Collaborations Future Plans

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Overall Research Plan

Continuously C ti l evolve l conceptual t l designs d i for f transformers t f using i
YBCO immersed in pressurized, subcooled nitrogen.
Near-term, develop FCL HTS analog for conventional unit. Risk reduction by first building single-phase single phase unit unit. Far-term, with low-cost conductor and refrigeration, develop HTS unit that exceeds conventional performance at same cost in smaller envelope.

Carry out high-voltage tests to qualify electrical insulation

systems up to 115-138 kV operating voltage and 650 kV BIL. Perform ac loss, , stability, y, and fault handling g tests on sub-scale test coils. Support development of suitable dewar vessels. Perform other materials tests as needed. NEW PHASE In FY2010, WES/ORNL team joined with SuperPower and Southern Calif. Edison in a successful proposal to develop a 28-MVA superconducting FCL transformer for SCEs Smart Grid site in Irvine, California.
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FY 2010 activity has centered on securing new funding composite dewar development, funding, development ac losses, and high-voltage insulation.
Funding Action DOE Smart Grid Regional
Demonstration funding has been approved for 28-MVA unit development. development Milestone Open-top composite dewar successfully passed four-month long-term test. Milestone Further ac loss tests on YBCO simulated HV coils were carried out. New insulation test coil was successfully tested to 550-kV BIL. Long-term testing will begin on epoxy resin bushing.
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DOE Smart Grid Regional Demonstration funding was awarded for a 28-MVA HTS FCL transformer.
Rating: 28-MVA; 70.5 kV / 12.47 kV; 132 A / 1296 A
13.1% impedance to match existing conventional units. Increase to 26% impedance p in HTS quench q gives g 50% reduction of fault current. Continuous operation at 40.6 MVA (145% of rated load) with extra liquid nitrogen supply. Normal operation at 70 K, 3.4 bar. HTS is sized for sufficient margin on 40.6-MVA current. Cryocoolers cycled to match heat loads at lower ratings ratings. Current leads are sized for 125% of 28-MVA current. Maximum current lead temperature rises to <120C at 40.6 MVA MVA.
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Conceptual Design
Conventional WES
manufacturing techniques will utilize experienced WES coil winders. Uses WES design software & ORNL design spreadsheet. 70-K pressurized, subcooled nitrogen is a good substitute for oil. HTS tape with parallel resistive conductor for stability and f lt handling. fault h dli Coil dewar surrounds warm steel core. Air-cooled core with blower. blower Proof of concept with singlephase Alpha-1 (normal conductor) and Alpha-2 (HTS) units. it
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2G-HTS Conductor Architecture Under Development

Original design used parallel copper.
Motivated by y ANSI requirement q for a conventional non-FCL transformer to recover normal operation after a 2-sec fault.

This had disadvantages:

Required q amount of copper pp is nearly y as much as in a conventional unit. Copper produces high eddy current losses.

Evaluating g alloy y options p for replacing p g copper. pp

High resistance after HTS quenches reduces fault current to about half that of conventional unit. Eddy current losses are reduced.

SCE substation has type CO-8 distribution breakers.

Opening time is ~1 sec in area of interest for 28 MVA. Conductor temperature will rise to roughly 250 K. Few-minute re-cool time.
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 HV Continuous disc winding;

The windings will be similar to WESs conventional design. design

single conductor, 8-12 turns/disc. LV Screw LV S winding; i di 8-12 8 12 conductors d t i in parallel. Transposed to give uniform current sharing. Windings will contain several individually-tested modules to limit amount of conductor at risk in a test failure. Standard 6 or 12 mm 2G HTS tape with high resistance alloy strip. Provides robust conductor that can be insulated on high-speed machine.
High-resistance alloy HTS Insulation
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28-MVA unit will be proof-tested at SCE MacArthur Substation-Irvine, Substation-Irvine CA. CA

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Technical Progress S. W. Schwenterly, ORNL

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 Dewar performed well in vacuum and thermal cycling tests in

FY2009. Paper at 2009 Cryo.Eng. Conference.

The open-top composite dewar passed long-term tests tests.

Small oil-free molecular drag pump station (5 l/s) could

maintain 10-3 torr warm, <10-4 torr cold.

Dewar was refilled once a week for

four months.

Boiloff increased from 0.14 to 0.16

liters/hr in first week, then constant.

Could valve off pump for 8 hr with no

effect on boiloff.

Could unplug pump to simulate power

outage with only small pressure rise.

Now being used routinely as a lab facility

for ac loss measurements.

Single-phase dewar procurement deferred

due to start of 28-MVA project.
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 AmSC 344S stainless stainless-clad clad HTS tape; co-wound co wound copper or stainless. stainless HTS tape is bare, insulation is only around co-wound conductor to prevent
buckling. 4-mm disc spacers machined from clear plastic. Simulated high voltage winding 26 six-turn discs, continuously wound by WES 4.4-mm WES, 44 t tape, 8 8.9 9 cm ID ID, 21 21.4 4 cm l length, th 50 m of f HTS t tape, 75 75-A A measured Ic (equivalent to 50 A rms).

Test coils help predict ac loss.

Electronic loss measurement with lockin amplifier external toroidal aircore bucking g transformer to cancel inductive signal g has been added.
Validation third coil with only copper showed the expected resistive losses, at both RT and 77 K.

New cryostat in the composite dewar with pumped LN bath allows testing
p , with no effect by y nearly y metal wall. at reduced temperature, Coil with co-wound copper was tested at reduced temperature and several frequencies in this dewar.
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Losses in HV prototype coils exhibit non-linear current dependence

Losses (Ipeak/Ic)n. Losses are similar for
co-wound d Cu C and d Stainless.

For Ipeak/Ic < 0.4, n ~

15 1.5.
Consistent with ferromagnetic Ni-W substrate

For Ipeak/Ic > 0.4, n ~ 2.

Eddy or coupling mechanism h i

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Losses in HTS/Cu coil varied as square of frequency q y and were temperature p independent. p
Dividing ac loss by square of frequency collapses the loss into one line. Loss proportional to square of the frequency also suggests coupling or eddy mechanism. h i

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Very little change in loss when temperature is lowered f from 77 K to t 72 K K suggests t most of loss from Cu or HTS substrate. HTS/SS coil will get similar tests.
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Presentation_name

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Losses are higher at the coil ends

Each VT pair covers 2 discs. Radial R di l fields fi ld at t ends d increase i losses. l

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Insulation studies for 550 kV BIL have continued. continued New WES Test Coil
Similar 350-kV BIL coil
Flashover HV LV

passed all tests in FY 2008 Standard WES design pressboard structure Copper conductor with WES polymer insulation LV & HV disc windings HV Tests in LN in Fall 2009

Bushing Test
Commercial 650 kV
BIL bushing successfully tested short-term in FY09 Long-term test planned for smaller 28-kV model

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Test Results - 550-kV Coil

HV coil was impulsed from top
with bottom & LV coil grounded. 77-K 77 K LN bath was pressurized to 1.8 bar absolute to stop boiling. Passed 3 impulse shots at -550 kV and 3 shots at + 501 kV kV. Warmed up and un-grounded the HV coil. Test with ac voltage showed 2.2 pC partial discharge at 102 kVac. Passed 1-min withstand at 201 kVac. 650-kV impulse tests planned if g available. funding
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FY 2010 Plans
Seek new funding options

FY 2010 Performance
DOE Smart Grid Regional
Demonstration funding g has been approved for 28-MVA FCL unit. Carried out further Ic and ac loss tests on YBCO sample coils with co-wound copper and stainless steel . New 115 KV/550 kV BIL coil passed 550kV impulse / 200 kV withstand; long-term bushing tests started. Long-term tests on small open-top dewar completed successfully; new procurement under consideration. WES programs are now in use for HTS unit designs. Replaced by new 28-MVA FCL unit project.

MilestoneYBCO ac loss and

Ic testing

Carry out further dielectric

testing

Milestone Mil t C Composite it d dewar

testing and procurement

Modify y WES transformer

design programs for HTS Begin 5/7-MVA single-phase prototype substation transformer
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Technology Transfer, Collaborations

New collaboration with SuperPower and SCE on a Smart Grid
proposal for fault current limiting transformers has received DOE funding approval.

Team possesses strong complementary abilities in research,

engineering, manufacturing, & utility operation.

Frequent site visits of about a week each each. 1X 1X ORNL to WES, WES
2X WES to ORNL, Smart Grid FCL transformer team meetings at WES and SP. Communication several times a week by phone and E-mail.

Team is working with suppliers to develop dewars and qualify

bushings. A 650-kV commercial bushing was used for impulse and ac withstand tests in LN.

Paper on composite dewar was presented at 2009 CEC/ICMC. Paper on coil ac loss measurements will be presented at 2010
Applied Superconductivity Conference.
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FY 2011 Plans
Support pp 28-MVA FCL unit conceptual p design g and engineering g g
analysis. Cryogenic, electrical, mechanical issues Support detail design of single-phase Alpha-1 unit with normal conductor Qualify YBCO materials for the reference design. Support SuperPower and WES in specification and production of HTS FCL conductor laminated to a resistive p metallic strip Test sample coils with SP conductor wound by WES in subcooled liquid nitrogen:

AC loss measurements on SP conductor in single- and multiple-tape coils Critical current and stability under operating conditions Fault current handling, recovery, and load restoration after fault

Address Technology Issues.

Continue long-term bushing tests in LN. Support WES in evaluation of dewar designs and purchase of single-phase test dewar for proof of concept.
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WES and ORNL continue to be committed to the development of HTS transformers.

We welcome the participation of SuperPower and SCE!

QUESTIONS?

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