asl 11 kv fcl for the ce electric grid, newcastle, uk low...

1

ASL 11 kV FCL for the CE Electric Grid, Newcastle, UK

Low-Carbon Network Fund Program Update

EPRI Superconductivity Conference

Tallahassee, Florida

October 12, 2011

Albert Nelson – [email protected]

Franco Moriconi – [email protected]

mailto:[email protected]

mailto:[email protected]

2

Overview

Brief Background of the Project

Initial Test Results

Bushing Failure and Corrective Action

Recovery and Repair Effort

Successful Retest and Acceptance

3

Saturable Iron Core MFCL

Operating Principle

Picture-Frame Iron-Cores

AC CoilAC Coil

Boost Buck

Configuration for single

phase FCL

BoostBuck

4

Evolution of the Product

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

5

Installation Late 2011

Specifications:Voltage: 11.3 kV

Current: 1250 A

Prospective Fault: 17 kA peak

Fault Reduction: 22%

Fault Duration: 3 seconds

CE Electric UK and Applied Superconductor Ltd(11 kV)

6

ASL MFCL Assembly – Major Components

7

ASL 11 kV MFCL Assembly – T&R Electric

8

ASL 11 kV MFCL Assembly – T&R Electric

9

ASL 11 kV MFCL Factory Tests

• Windings Resistance

• Windings Reactance

• From Insertion Impedance Voltage Drop

• Insulation Resistance

• Temperature Rise

• AC Withstand Voltage

10

ASL 11 kV MFCL First Test Protocol

(Factory Tests Highlighted)

Document Section Test Name Specification Clarification Test Location

a) At Reduced Voltage a) Factory

b) At Full Voltage b) High Power Lab

a) At Reduced Voltage a) Factory

b) At Full Voltage b) High Power Lab

Factory and High

Voltage Lab

4.1.6 Temperature Rise

IEC 60076 Part-6,

Clause 8.9.11

&60076 Part2

At Reduced Voltage. Test at 1250A until

steady state, then 15 min at 1600A, longer if

limit not reached Factory

4.1.7 Partial Discharge IEC 60270

Each phase in turn, remaining phases and

frame earthed High Power Lab

4.1.8 Inter-turns Insulation

IEC 60076-6,

Clause 8.9.9

Test@95kV Peak. Nom. 1.2x50. Each phase

in turn, remaining phases and frame

earthed. 15+ve, 15-ve pulses on each

phase High Voltage Lab

4.1.9 BIL (Lightning Impulse)

60076-6,

Clause 8.9.12&

IEC 60076-4,

Clause 7

Test@95kV Peak. Nom. 1.2x50. Each phase

in turn, remaining phases and frame

earthed. 15+ve, 15-ve pulses on each

phase High Voltage Lab

4.1.2 Insulation Resistance

IEEE Std. 62-

1995, Clause

6.1.5 Coil manufacturer dielectric test Factory

(1) Prosp. Asym.=17kA peak,

(2) Prosp. Sym.= 6.2kArms

(1) Limited Asym. < 13.25 kA peak,

(2)Limited Sym. < 5kArms

Loss Measurement

IEC 60076 Part-6,

Clause 8.9.7

4.1.5 AC Withstand Voltage

IEC 60076-6

Clause 8.9,8

& IEC 60076-3,

28kV for 1-minute each phase in turn,

remaining phases and frame earthed

SP

EC

IAL

TE

ST

S

4.3.1

Faulting with FCL bypassed at

rated voltage (11.3kV) to verify for

IEC 60076 Part-5,

Clauses 4.2.2 to

RO

UT

INE

TE

ST

S

4.1.3 Insertion Impedance (Voltage Drop)

IEC 60076 Part-6,

Clause 8.9.5

4.1.4

High Power Lab

4.3.2

Faulting with FCL in the circuit at

rated voltage (11.3kV). Test at 17

IEC 60076 Part-5,

Clauses 4.2.2 to High Power Lab

11

ASL 11 kV MFCL Factory Testing Inductance Measurements

ASL 11 kV - Terminal Inductance at Full Load 1250 Arms vs. DC Magnetization

Measured at 60Hz - Calculated at 50Hz

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

310

320

330

340

350

360

370

380

360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520

DC Magnetization [kAT]

Term

inal

Ind

uct

ance

[m

icro

H]

0.6

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

1.05

1.1

1.15

1.2

1.25

1.3

1.35

1.4

1.45

1.5

1.55

1.6

1.65

1.7

1.75

1.8

Equ

ival

ent

Rel

ativ

e P

erm

eab

ility

Mu

r

MeasuredTerminalInductance

ANSYS CalculatedTerminalInductance

Inductance limitfor 100VrmsVoltage Drop255 microH

Measured Air-CoreTerminal Inductance189 microH

Minimum DC Magnetization450 kAT

EquivalentRelativePermeability

12

ASL 11 kV MFCL Factory Testing – Temperature Rise

• 17 hours at full load 1250 A rms

• Top Radiator Oil temperature

from 26 C to 73 C

• Bottom Radiator Oil temperature

from 19 C to 40 C

• Average Temperature Rise 34 C

AC Current 1250 Arms

Top Radiator Oil Temp [C]

Bottom Radiator Oil Temp [C]

13

ASL 11 kV MFCL Factory Testing – Voltage Withstand

• Over-voltage is applied to verify external insulation and dielectric strength

• 28 kV voltage was applied for 60 seconds

• The FCL successfully endured the voltage withstand test of 28 kV ph-ph for 1 minute, as per Table 2 of IEC

60076-3, without voltage collapse

14

ASL 11 kV MFCL Factory Testing

AC Voltage Drop Versus DC Current

DC vs. AC

0

50

100

150

200

250

300

350

400

450

500

550

600

650

700

750

800

850

900

950

1000

1050

1100

1150

1200

1250

1300

1/7/

11 5

:02

PM

1/7/

11 5

:16

PM

1/7/

11 5

:31

PM

1/7/

11 5

:45

PM

1/7/

11 6

:00

PM

1/7/

11 6

:14

PM

1/7/

11 6

:28

PM

1/7/

11 6

:43

PM

1/7/

11 6

:57

PM

1/7/

11 7

:12

PM

1/7/

11 7

:26

PM

1/7/

11 7

:40

PM

1/7/

11 7

:55

PM

1/7/

11 8

:09

PM

1/7/

11 8

:24

PM

1/7/

11 8

:38

PM

1/7/

11 8

:52

PM

1/7/

11 9

:07

PM

1/7/

11 9

:21

PM

1/7/

11 9

:36

PM

Date and Time

AC

Cu

rren

t [A

rms]

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

DC

Cu

rren

t [A

]

AC

Vo

ltag

e D

rop

[V

rms]

ASL-12kV.ASL_AcInfo.PhaseACurrent

ASL-12kV.ASL_HtsCoil1.Current

ASL-12kV.ASL_AcInfo.PhaseAVoltage

15

ASL 11 kV FCL Factory Testing

Typical HTS Coil Temperature Rise

HTS COIL 2 - BOTTOM FCL

15

16

17

18

19

20

21

22

23

24

25

1/7/

11 5

:02

PM

1/7/

11 7

:26

PM

1/7/

11 9

:50

PM

1/8/

11 1

2:14

AM

1/8/

11 2

:38

AM

1/8/

11 5

:02

AM

1/8/

11 7

:26

AM

1/8/

11 9

:50

AM

1/8/

11 1

2:14

PM

1/8/

11 2

:38

PM

1/8/

11 5

:02

PM

Date and Time

Cry

og

enic

s T

emp

erat

ure

s [k

]

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

Cu

rrre

nt

and

Vo

ltag

e [A

rms,

Vrm

s]

ASL-12kV.ASL_HtsCoil2.LsTemp1








ASL-12kV.ASL_AcInfo.PhaseACurrent

ASL-12kV.ASL_HtsCoil1.Current

ASL-12kV.ASL_AcInfo.PhaseAVoltage

16

ASL 11 kV MFCL Factory Testing

AC Coil Temperature Rise

AC Windings and Oil Temperature Rise

0

20

40

60

80

100

120

140

1/7

/11

2:2

4 P

M

1/7

/11

7:1

2 P

M

1/8

/11

12

:00

AM

1/8

/11

4:4

8 A

M

1/8

/11

9:3

6 A

M

1/8

/11

2:2

4 P

M

1/8

/11

7:1

2 P

M

1/9

/11

12

:00

AM

1/9

/11

4:4

8 A

M

1/9

/11

9:3

6 A

M

Te

mp

era

ture

[C

]

ASL-12kV.ASL_AcTank.Temp1








17

High-Power Testing at KEMA Powertest, Chalfont, PA

18

First-Round Design and Special Acceptance Testing

Testing conducted 15-17 February 2011, KEMA Powertest, Chalfont, PA

One load circuit calibration shot

Seven fault circuit calibration shots

Six load through test device shots

Nine fault through test device shots

Varying DC bias currents, fault duration (12.5 cycles and 3 seconds – 150 cycles) and with and without load

current

Four additional transient recovery voltage tests were performed – two with the test device in the circuit and two

with equivalent three-phase air-core reactors in the circuit

Test results were mixed:

Outstanding HTS DC performance during three-second event

Satisfactory DC saturation and acceptable insertion impedance voltage drop at rated current

Generally acceptable fault limiting results – about 13.8 – 13.9 kA best performance due to bolted versus

grounded fault

Failed post-test HV testing – partial discharge detected on bushing during 28 kV voltage withstand test

19

Test Setup

11 kV MFCL Test Set-Up

MB Master Breaker

ABUB Auxiliary Back Up Breaker

MS Making Switch

AUX Auxiliary Breaker

20

-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3

-15

-10

-5

0

5

10

15

TEST 16 - ASL 11kV FCL - FAULT LEVEL 17 kApeak 6.2 kArms Prospective - PhA asymmetry

Time [sec]

LIN

E C

UR

RE

NT

[kA

]

I prospective

Ia Limited

Ib Limited

Ic Limited

11 kV MFCL Test - Three-Phase Fault, 250 ms

-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3

-5

0

5

10

15


Time [sec]

LIN

E C

UR

RE

NT

[kA

]

I prospective

I Limited - 90A DC Bias

21

Grounded versus Bolted Fault Limiting Performance

22

Test Results – 3 second fault

0 0.5 1 1.5 2 2.5 3-15

-10

-5

0

5

10

15TEST 22 - ASL 11kV FCL - FAULT LEVEL 17 kApeak 6.2 kArms Prospective - PhC asymmetry - Reverse Polarity 3s

Time [sec]

LIN

E C

UR

RE

NT

[kA

]

Ia 90A DC Bias

Ib 90A DC Bias

Ic 90A DC Bias

11 kV MFCL Test – Three-Phase Fault, 3 Seconds

23


0 0.5 1 1.5 2 2.5 380

90

100

110

120

130


Time [sec]

DC

CU

RR

EN

T [

A]

I HTS1 90A DC Bias

I HTS2 90A DC Bias

11 kV MFCL Test – DC Current During 3-Second Fault

24


0 0.5 1 1.5 2 2.5 3-6

-5

-4

-3

-2

-1

0

1


Time [sec]

DC

VO

LT

AG

E [

V]

V HTS1 90A DC Bias

V HTS2 90A DC Bias

V HTS Total 90A DC Bias

11 kV MFCL Test – DC Voltage During 3-Second Fault

HTS Voltage is 4 V during 3-second fault

25

B-Phase HV Bushing Failure

11 kV MFCL Test – AC Voltage Withstand Test

26

ASL 11 kV MFCL – Original Bus-Work Configuration

27

ASL 11 kV MFCL – Maximum Bus-Work Forces FEA

28

ASL 11 kV MFCL – Upgraded Bus-Work Concept

29

ASL 11 kV MFCL – Upgraded Bus-Work as Installed

30

ASL 11 kV MFCL – Detail of Flex Connectors

31

MFCL TRV Effects Testing

Analytical studies and full-power testing suggest that MFCLs have significantly lower impact on circuit-breaker TRV

compared to an equivalent air-core series reactor

Fast transient oscillations in the TRV due to a combination of low capacitance and high inductance are reduced

It should be possible to install MFCLs in circuits without incorporating TRV mitigation measures such as external

capacitors

32

ASL 11 kV MFCL Post-Repair Retest

Complete retest performed week of September 26, 2011

Acceptance and special test protocol modified to add additional, more rigorous tests

HV test regime performed before and after fault testing

Four Short Circuit Calibration tests performed (One per phase plus a three-second prospective)

Six Fault tests performed (Two per phase, maximum asymmetry on each phase, and reverse polarity)

Five 250 ms fault tests

One 3-second fault test

Verified pre-fault load current, insertion impedance, and post-fault recovery

All tests completed satisfactorily

Post-test inspection inside tank (lid-off) confirmed mechanical fastener and structural integrity

Voltage-drop, load, fault limiting and other tests were virtually identical to first-round test results

No change in voltage drop insertion impedance (100 V at 1.25 kA)

No change in fault limiting performance

33

Revised Test Protocol for Post-Repair Retest

34

Short Circuit Tests – Comparison Set 1 vs. Set 2

Set 1 - February 2011 Set 2 - September 2011

0 0.5 1 1.5 2 2.5 3-15

-10

-5

0

5

10


Time [sec]

LIN

E C

UR

RE

NT

[kA

]

Ia 90A DC Bias

Ib 90A DC Bias

Ic 90A DC Bias

0 0.5 1 1.5 2 2.5 3-15

-10

-5

0

5

10

15TEST 13 - ASL 11kV FCL - FAULT LEVEL 17 kApeak 6.2 kArms Prospective - PhC asymmetry

Time [sec]

LIN

E C

UR

RE

NT

[kA

]

Ia 110A DC Bias

Ib 110A DC Bias

Ic 110A DC Bias

-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3

-5

0

5

10

15


Time [sec]

LIN

E C

UR

RE

NT

[kA

]

I prospective

I Limited - 90A DC Bias

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35

-5

0

5

10

15


Time [sec]

LIN

E C

UR

RE

NT

[kA

]

Iprospective

Ia 110 DC Bias

35

0 0.5 1 1.5 2 2.5 3100

110

120

130

140


Time [sec]

DC

CU

RR

EN

T [A

]

I HTS1 110A DC Bias

I HTS2 110A DC Bias

0 0.5 1 1.5 2 2.5 380

90

100

110

120

130


Time [sec]

DC

CU

RR

EN

T [

A]

I HTS1 90A DC Bias

I HTS2 90A DC Bias

0 0.5 1 1.5 2 2.5 3-6

-5

-4

-3

-2

-1

0

1


Time [sec]

DC

VO

LT

AG

E [

V]

V HTS1 90A DC Bias

V HTS2 90A DC Bias


0 0.5 1 1.5 2 2.5 3-5

-4

-3

-2

-1

0

1

2


Time [sec]

DC

VO

LT

AG

E [V

]

V HTS1 110A DC Bias

V HTS2 110A DC Bias


Short Circuit Tests – Comparison Set 1 vs. Set 2

Set 1 - February 2011 Set 2 - September 2011

36

Summary

Testing conducted 15-17 February 2011, KEMA Powertest, Chalfont, PA

Initial test results were generally satisfactory, but acceptance testing failed due to HV

retest failure (cracked bushing)

Bushing failure traced to excessive bus-work forces during faults

Rework of bus design to strengthen bus-work and isolate bushing terminations from loads

Retest 26-28 September 2011 successful – MFCL accepted by client

asl 11 kv fcl for the ce electric grid, newcastle, uk low...

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