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=5.533
Q=-0.3882
V=1.044
V
A
Shandin
L_CB1
L_CB1
#1
#2
#3
L_CB4
L_CB4
L_CB3
L_CB3
Timed
Breaker
Logic
Closed@t0
Timed
Breaker
Logic
Closed@t0
Timed
Breaker
Logic
Closed@t0
SHANDIN
115-12kV
P=5.535Q=-0.3298
V=120
V
ARL
VFPh
RRL
0.001[uF]
0.001[uF]
0.001[uF]
#1
#2
#3
#1
#2
#3
Avanti
12kV,1200A
FCL
Line Load
Ifa2 Ifa2
Ifb2 Ifb2
Ifc2 Ifc2
Vs
Freq
Phase
ZPPlots_PHASE_ALL
Tested@GridVoltage=120kVwithreducedcircuit
ModifiedFaultONRESISTANCE=0.01OHM
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
Timed
Fault
Logic
fault
fault
fault
Main...
fault
0
O C
SW
SW
SW
Main...
SW
0
O C
RMS
Ifa2_RMS
Ifa2_RMS
RMS
Ifc2_RMS
Ifc2_RMS
RMS
Ifc2_RMS
Ifb2_RMS
Ia4 Ia4
Ib4 Ib4
Ic4 Ic4
RMS
Ia4_RMS
Ia4_RMS
RMS
Ic4_RMS
Ic4_RMS
RMS
Ib4_RMS
Ib4_RMS
GS1536
RCS1088
PMH_4331
1.2[MVAR]
CAPSW
1.279[MVAR]
-0.006076[MW]
CAPSW
sw4
sw4
P=3.018
Q=-1.703
V=1.033
V
A
P=1.583
Q=-1.138
V=1.032
V
A
P=0.3502
Q=0.1735
V=1.037
V
A
2,031'
1000XLP
GS1547
P=0.3217
Q=0.1602
V=1.033
V
A
2,072'
1000XLP
100'
1000XLP
1,324'
1000XLP
Main...
CAPSW
0
C O
P=0.3209
Q=0.16
V=1.032
V
A
bus1007
LOAD2
0.32[MW] 0.16[MVAR]
0.3[MW] 0.15[MVAR]
P=5.137
Q=-0.6407
V=1.037
V
A
P=3.822
Q=-1.303
V=1.033
V
A
P=3.5
Q=-1.463
V=1.033
V
A
PI
COUPLED
SECTION
PI
COUPLED
SECTION
OS1478
6,415'
1000XLP
PI
COUPLED
SECTION
GS1546
3,638'
1000XLP
PI
COUPLED
SECTION
GS4269
P=4.786
Q=-0.8141
V=1.037
V
A
5,160'
1000XLP
PI
COUPLED
SECTION
PI
COUPLED
SECTION
RCI_1449
PI
COUPLED
SECTION
900'
1000XLP
P=0.7825
Q=0.3896
V=1.032
V
A
PI
COUPLED
SECTION
1,448'
1000XLP
PME2349
P=0.3911
Q=0.1946
V=1.032
V
A
PI
COUPLED
SECTION
1,109'
1000XLP
J988
1,808'
750XLP
PI
COUPLED
SECTION
PI
COUPLED
SECTION
Main...
sw4
0
C O
RCI_1453
P=1.582
Q=-1.138
V=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'
350XLP
PI
COUPLED
SECTION
PS2062
645'
336ACSR-Multigrounded
336ACSR
P=0
Q=0
V=0
V
A
0.32[MW] 0.16[MVAR]
P=0.3536
Q=0.1748
V=1.039
V
A
0.32[MW] 0.16[MVAR]
P=0.3459
Q=0.1719
V=1.034
V
A
0.32[MW] 0.16[MVAR]
P=0.5918
Q=0.2891
V=1.033
V
A
0.55[MW] 0.27[MVAR]
P=0.3217
Q=0.1602
V=1.033
V
A
0.30[MW] 0.15[MVAR]
P=0.3213
Q=0.1601
V=1.032
V
A
0.30[MW] 0.15[MVAR]
0.30[MW] 0.15[MVAR]
P=0.3913
Q=0.1951
V=1.032
V
A
0.366[MW]0.183[MVAR]
P=0.3911
Q=0.195
V=1.032
V
A
0.366[MW]0.183[MVAR]
P=0.3912
Q=0.1951
V=1.032
V
A
0.366[MW]0.183[MVAR]
P=0.3955
Q=0.1951
V=1.032
V
A
0.37[MW] 0.183[MVAR]
P=1.583
Q=-1.138
V=1.032
V
A
P=0.4047
Q=-1.723
V=1.032
V
A
P=0.7865
Q=0.3891
V=1.032
V
A
E4201965
548'
1000XLP
PI
COUPLED
SECTION
P=0.1608
Q=0.0801
V=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]
FCLbackemf[kV]
1
2
3
4
5
FCLGain-KFCL
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 Modem Wonderware
Servers
W.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 second
3.5 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]

2x1
3x2
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
CURRENT[kA]VOLTAGEinBlue[kV]
TIME [sec]

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
CURRENT[kA]
TIME [sec]
* FCL Terminal Voltage in Blue

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
DEMONSTRATOR
TO
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 Transformer
138 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)

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
3x2
6x1

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
I
dc
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]
Resistance[ohms/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.

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

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