superconducting design, construction and testing magnet … · strategy for hts based...
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High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 1
Superconducting Magnet Division
Design, Construction and Testing
of a Large Aperture
High Field HTS SMES Coil
R. Gupta, M. Anerella, P. Joshi, J. Higgins,
S. Lakshmi, W. Sampson, J. Schmalzle, P. Wanderer
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 2
Superconducting Magnet Division
Overview
Strategy for HTS based Superconducting
Magnetic Energy Storage (SMES) Systems
Design, Construction and Testing of SMES Coil
Ground Breaking Results
Summary – take away for future
Acknowledgment
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 3
Superconducting Magnet Division
SMES Options with HTS High Temperature Option (~65 K): Saves on cryogenics (Field ~2.5 T)
High Field (~25 T) Option: Saves on Conductor (Temperature ~4 K)
High
Temperature
SMES Ring
High
Field
SMES
Ring
Significant attempts:
LTS: 5 T, 4 K (BPA, USA)
HTS: Medium field, high temperature
Cost analysis of HTS option:
Presently, conductor cost dominates the
cryogenic cost by an order of magnitude
Also interesting: Medium field, medium temperature option
(depending on the application and the future cost of HTS)
High field 4 K HTS could be game changer:
Very high fields: 25-30 T (E α B2)
Only with HTS (high risk, high reward)
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 4
Superconducting Magnet Division
Cost Considerations of HTS SMES for GRIDS
10
102
103
104
0 5 10 15 20 25 30 35 40 45
Wh
ole
Wir
e C
riti
cal C
urr
en
t D
en
sity
(A
/mm
², 4
.2K
)
Applied Magnetic Field (T)
YBCO: B ∥ Tape plane
YBCO: B ⊥ Tape plane
Bi-2212: OST NHMFL 100 bar OP
Bi-2223: B ⊥ Tape plane (prod.)
Nb₃Sn: Internal Sn RRP®
Nb-Ti: LHC 4.2 K
Nb-Ti: Iseult/INUMAC MRI 4.22 K
YBCO B∥ Tape Plane
YBCO B⊥Tape Plane
2212
High-Jc Nb3Sn
Compiled from ASC'02 and ICMC'03 papers
(J. Parrell OI-ST)
666 filament OST strand with NHMFL 100 bar
Over-Pressure HT
2223: B⊥ Tape Plane
Sumitomo Electric (2012 prod.)
SuperPower "Turbo" Double Layer Tape, measured at NHMFL 2009
Nb-Ti4.2 K LHC insertion quadruole strand
(Boutboul et al. 2006)
4.22 K High Field MRI srand (Luvata)
Nb-Ti
April 2014
For large applications, amount of HTS used
drives the cost. To reduce YBCO cost:
• Design for field favorable direction (torus)
• Develop high field technology
In HTS, critical current falls slowly
Energy increases rapidly (as B2)
High field HTS magnets pose huge challenges
Large stresses
Quench protection
New conductor
Nothing like this has ever been done before !
25-30 T large bore magnets would be really
interesting but
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 5
Superconducting Magnet Division
Unique Opportunity
… ARPA-E’s mission is to catalyze and accelerate
the creation of transformational energy
technologies by making high-risk, high-reward
investments in their early stages of development
Such missions provide a unique opportunity
ARPA-E: Advanced Research Project Agency - Energy
Even partial success breaks new grounds
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 6
Superconducting Magnet Division
Superconducting Magnet Energy Storage System
with Direct Power Electronics Interface
Project Goal:
Competitive, fast response, grid-scale MWh
superconducting magnet energy storage (SMES) system
Team member major contributions:
ABB: Power electronics, Lead
BNL: SMES coil and Superconducting switch
SP: 2G HTS manufacture and improved production
UH: Wire manufacturing process research
funded by
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 7
Superconducting Magnet Division
Focus of the Presentation
Technology for High field HTS SMES coil
– Design, construction and test results
For economic viability of a large scale energy storage system, cost of HTS must come down significantly
The technology developed and demonstrated as a part of this project could already be applied to special purpose storage system and other applications
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 8
Superconducting Magnet Division
The Basic Demo Module
• Field: 25 T@4 K
• Bore: 100 mm
• Stored Energy: 1.7 MJ
• Hoop Stresses: 400 MPa
• Conductor: ReBCO
Aggressive parameters:
Amount of ReBCO used: >6 km, 12 mm wide
Significant use of HTS in a high field application
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 9
Superconducting Magnet Division
Guiding Principles
• High strength ReBCO tape with advanced pinning (SuperPower)
• Co-wind with stainless steel insulating tape for high strength
– Stainless steel insulation also helps in quench protection
• Subdivide structure to keep stress accumulation within limit
• Use copper discs for uniform cooling and to reduce thermal strain
– Copper discs also help in rapid energy extraction after quench
• Advanced quench protection system
• Strong QA with several intermediate tests (R&D conductor)
Each pancake was tested at 77 K
Intermediate high current 4 K tests
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 10
Superconducting Magnet Division
Conductor Specifications
Formal specs at 77 K
Informal specs at 4 K
• Minimum Ic (@4K, 8T) : 700 A (irrespective of angle)
Significant variation in performance found
Cu: 65 mm and 100 mm
Two values for electrical and mechanical grading
12 mm wide tape with Hastelloy substrate
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 11
Superconducting Magnet Division
Design Optimization of Demo Module
|B|
~26 T ~7 T
Fie
ld p
erp
end
icu
lar
Coil winding adjusted for grading:
• Cu thickness in HTS tape (65 and 100 mm)
• SS tape thickness (65 and 100 mm)
(more copper in ends; more SS in center)
End Result : Improved performance
Reduced B and better mechanical structure
In torus, field is
primarily parallel
in ends (higher Ic)
In demo, outer
coils are made
shorter for that
208 182
220
258
215
270
Number of turns per pancake
(for the same coil i.d. and o.d.)
Current
density
J (A/mm2)
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 12
Superconducting Magnet Division
Mechanical Structure
• Stainless steel tubes to contain the hoop stress
• The magnet was radially divided in two coil layers (inner and outer) with stainless
steel tubes in between to reduce stress build up
• Use high strength conductor - ReBCO with Hastelloy substrate from SuperPower
• Co-winding with metallic insulation (Stainless Steel) rather than inorganic
(Kapton) to increase the modulus of the coil
• Stainless steel thickness increased in the middle (high stress) area
• Parameters to keep the stress & strain (hoop and axial) below the conductor limit
Stress
< 500 MPa
Strain
< 0.3% Stress Strain
S.L. Lalitha and R.C. Gupta, “The Mechanical Design
Optimization of a High Field HTS Solenoid”@ASC2014
Same principle as in PBL/BNL solenoid for Muon collider
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 13
Superconducting Magnet Division
Coil Construction
(and quality assurance)
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 14
Superconducting Magnet Division
HTS Single Pancake
V-taps for QA
This Outer: ~210 meter (258 turns)
HTS is not a production conductor yet and it was treated that way
Conductor inspected physically during the coil winding
Each coil was tested at 77 K with many v-taps to find significantly
lower performing sections, if any
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 15
Superconducting Magnet Division
77 K Test of a Series of Double Pancakes (inner)
Critical current (@1 µV/cm)
Two single
pancakes
powered in
series
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 16
Superconducting Magnet Division
Double Pancake 77 K Test Results (3 types)
Pancakes with similar
critical currents (Ic) Pancakes with
different Ic
One pancake good and the
other pancake defective
V-taps isolated
the bad sections
Importance of
77 K QA Test 0
1
2
3
4
0 20 40 60 80 100 120
Vo
ltag
e (
mV
)
Current (A)
(0-10)
(10-25)
(25-50)
(50-75)
0
1
2
3
4
0 20 40 60 80 100 120
Vo
ltag
e (
mV
)
Current (A)
(0-10)
(10-25)
(25-50)
(50-75)
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 17
Superconducting Magnet Division
High Current
Intermediate Tests
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 18
Superconducting Magnet Division
Double Pancake Coil Test
0
200
400
600
800
1000
1200
0 10 20 30 40 50 60 70 80
I c (A
) @
0.1m
V/c
m
Temperature (K)
Top Coil
Bottom Coil
Nom
inal
des
ign
cu
rre
nt:
~700 A
The option of operating over a large range (the benefit of HTS)
Ramp rate
up to 10 A/s
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 19
Superconducting Magnet Division
12 Pancake Coil Test
0
100
200
300
400
500
600
700
800
0 1 2 3 4 5
Cu
rre
nt (
A)
Time (sec)
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
4:09:07 PM 4:14:53 PM 4:20:38 PM 4:26:24 PM 4:32:10 PM 4:37:55 PM 4:43:41 PM 4:49:26 PM
Cu
rre
nt (
A)
Time
Charge Quench
• Energy (~125 kJ) extracted and dumped in the external resistor
• 77 K re-test (after quench) showed that the coil remained healthy
11.4 T in 100 mm bore
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 20
Superconducting Magnet Division
Final SMES Coil
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 21
Superconducting Magnet Division
Coils, Test Fixtures and Support Structure
Pancake coils: inner and outer
11 T, 760 A coil and fixture
77 K Test Fixture for outer
Outer Support Tube for
Inner
Outer Assembly Tube for
Outer
Outer Support Tube for
Outer Inner Assembly Tube for
Inner Copper Discs
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 22
Superconducting Magnet Division
Special Considerations
• Tasks were challenging – no such device with design parameters
near this (25 T, 100 mm, new R&D conductor) ever built.
• The program was on the fast track (3 years) with a limited R&D
and a limited funding.
• This was not a normal technology development program with a
series of tests planned. Project limits permitted one attempt only.
• Conductor was showing a significant variation in properties. One
weak link in over 6 km conductor had a potential of limiting the
performance of the entire system.
• We installed additional current leads to electrically bypass a
weaker performing coil, if needed. The idea was to demonstrate
maximum achievable field in one test run with minor adjustments.
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 23
Superconducting Magnet Division
Inner and Outer Coils Assembled with Bypass Leads
Inner Coil (102 mm id, 194 mm od)
28 pancakes
Outer Coil (223 mm id, 303 mm od)
18 pancakes
Total: 46 pancakes
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 24
Superconducting Magnet Division
Final Assembly
Outer inserted over inner coil SMES coil in iron laminations
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 25
Superconducting Magnet Division
Test of Quench Protection System at 77 K
Power supply was shut off and energy extracted when the quench
threshold reached. No degradation in coil performance observed
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 26
Superconducting Magnet Division
SMES Coil Test @50% Critical Current Reached at 27 K
0
50
100
150
200
250
300
350
400
14:24 15:36 16:48 18:00 19:12 20:24 21:36
Coil Current
Cu
rren
t (A
)
Time (hh:mm)
12.5 Tesla at 27 K
Record field/energy density in a superconducting
magnet at a temperature of 10 Kelvin or higher
27 K possible
with
liquid Neon
350 Amp
425 kJ
id:102 mm
od:303 mm
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 27
Superconducting Magnet Division
An Incident During the Test
• The ambitious design goal was: 1.7 MJ at ~700 A with 25 T at 4 K.
• We ramped the unit several times between 20-80 K. The test run at
350 Amp - 12.5 T at 27 K was already a record demonstration.
• During one such tests, the system tripped due to a data entry error
at ~165 A – well below the current the coil was powered earlier.
• This trip resulted in arcing between two current leads in the inner
coil and some damage. This was not part of the normal magnet
construction. These leads were added to bypass weaker coil.
• The issue is not related to the high field HTS SMES technology.
• The coil still has the potential to reach higher fields after repair.
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 28
Superconducting Magnet Division
Quench
Protection
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 29
Superconducting Magnet Division
Quench Protection Strategy at BNL
BNL has relied on a multi-prong approach for quench protection in a large number of HTS coils/magnets built and tested to date 1. Stainless steel (metallic) turn-to-turn insulation to spread energy after the quench
2. Inductively coupled copper disks to transfer energy instantaneously out of HTS coils, heat up coils and reduce current to provide extra margin at a critical time
3. Sensitive electronics to detect resistive voltage quickly at the pre-quench phase
4. Fast energy extraction with electronics that can tolerate high voltage stand-off
5. Quench heaters, used in LTS magnets, could be used in HTS also (used at NHMFL)
Note: Some of above methods are associated with energy loss
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 30
Superconducting Magnet Division
0
100
200
300
400
500
600
700
800
0 1 2 3 4 5
Cu
rre
nt (
A)
Time (sec)
0.E+00
1.E+05
2.E+05
3.E+05
4.E+05
5.E+05
6.E+05
0 1 2 3 4 5
I2(A
mp
2)
Time (sec)
0.E+00
1.E+05
2.E+05
3.E+05
4.E+05
5.E+05
6.E+05
2.5 2.502 2.504 2.506 2.508 2.51I2
(Am
p2)
Time (sec)
Copper Discs for Energy Extraction
Most action
in milliseconds
This fast extraction
also adds margin at
the critical time
Inductively coupled cooper discs
between two double pancakes
Over half
removed
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 31
Superconducting Magnet Division
SUMMARY • ARPA-E SMES provided a unique opportunity for using a large
amount of HTS (over 6 km, 12 mm wide SuperPower high strength
ReBCO tape) in a demanding 4 K, high field magnet application.
• The goal of achieving 25 T, in a significant aperture (~100 mm)
superconducting magnet with large hoop stresses (~400 MPa) and
new material was too aggressive to be met in one attempt only.
• Demonstration of a 12.5 T SMES coil at 27 K is highly promising.
It exceeded all previous demonstrations. This development should
encourage special applications of medium field HTS SMES.
• The incident which terminated the test doesn’t reflect a limit of
high field HTS technology. There is still significant potential.
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 32
Superconducting Magnet Division
Acknowledgement • ARPA-E for providing funding for this “high-risk, high reward” R&D.
• VR V. Ramanan (PI for the SMES project) and Eddy Aelozolia of ABB for
convertor and providing administrative support.
• BNL management for strong support to the development of quench protection
system and success of the overall program.
• Qiang Li for initiating this collaboration. Qiang Li and Vyacheslav Solovyoy for
the superconducting switch.
• BNL technicians Glenn Jochen, Sonny Dimaiuta, William McKeon, Ray Ceruti
and high school/undergraduate student Eric Evangelou for winding HTS coils
and helping in assembling and testing the SMES.
• Drew Hazelton (SuperPower) and Venkat Selvamanickam (University of
Houston) for expertise and feedback on the High Temperature Superconductor.
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 33
Superconducting Magnet Division
Backup Slides
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 34
Superconducting Magnet Division
Design Parameters of BNL Demonstration Coil
Stored Energy 1.7 MJ
Currrent 700 Amperes
Inductance 7 Henry
Maximum Field 25 Tesla
Operating Temperature 4.2 Kelvin
Overall Ramp Rate 1.2 Amp/sec
Number of Inner Pancakes 28
Number of Outer Pancakes 18
Total Number of Pancakes 46
Inner dia of Inner Pancake 102 mm
Outer dia of Inner Pancake 194 mm
Inner dia of Outer Pancake 223 mm
Outer dia of Outer Pancake 303 mm
Intermediate Support 13 mm
Outer Support 7 mm
Width of Double Pancake 26 mm
High field and big
radius create large
stresses (~400 MPa)
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 35
Superconducting Magnet Division
77 K Test of a Series of Double Pancakes (outer)
O1
-1
O1
-2
O2
-1
O2
-2
O9
-1
O9
-2
O3
-1
O3
-2
O4
-1
O4
-2
O7
-1
O7
-2
O8
-1
O8
-2
O5
-1
O5
-2
O6
-1
O6
-2
0
25
50
75
100
125
150
175
200
225
250Outer double pancake coils
I c (A
) b
ase
d o
n 0
.1m
V/c
m c
rite
rio
n
Single pancake coil ID
n-value
Type A -CC(160 mm) + SS (25 mm)
Measured value, Beyond range
Type B -CC(160 mm) + SS (50 mm)
Measured value, Beyond range
Type C -CC(120 mm) + SS (25 mm)
Measured value, Beyond range
Type D -CC(120 mm) + SS (50 mm)
Measured value, Beyond range
HTS coils are 100%
cold tested at 77 K as
a standard QA in all
HTS Magnet
programs at BNL
S.L. Lalitha, W.B. Sampson and R.C. Gupta,
“Test Results of High Performance HTS Pancake
Coils at 77 K,” presented @MT23
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 36
Superconducting Magnet Division
Inner and Outer Coils
Inner (in support tube) Outer (prior to support tube)
High Field HTS SMES Coil R. Gupta, ..., BNL Seoul, S. Korea Oct 19, 2015 37
Superconducting Magnet Division
Preparation for the Final Test