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High-Temperature Super Conducting Fault-Current dti HIGH-TEMPERATURE SUPER­ CONDUCTING FAULT-CURRENT LIMITER Optimisation of Superconducting Elements CONTRACT NUMBER: K/EL/00304/00/00 URN NUMBER: 04/1488 The DTI drives our ambition of ‘prosperity for all’ by working to create the best environment for business success in the UK. We help people and companies become more productive by promoting enterprise, innovation and creativity. We champion UK business at home and abroad. We invest heavily in world-class science and technology. We protect the rights of working people and consumers. And we stand up for fair and open markets in the UK, Europe and the world. ii High-temperature Superconducting Fault-current Limiter - Optimisation of Superconducting Elements K/EL/00304/00/REP URN 04/1488 Contractor VA TECH T&D UK Ltd The work described in this report was carried out under contract as part of the DTI Technology Programme: New and Renewable Energy, which is managed by Future Energy Solutions. The views and judgements expressed in this report are those of the contractor and do not necessarily reflect those of the DTI or Future Energy Solutions. First published 2004 © V A Tech copyright 2004 ii i EXECUTIVE SUMMARY Introduction This project was undertaken with VA TECH T&D UK Ltd as lead partner, in conjunction with the Interdisciplinary Research Centre in Superconductivity (IRC) of the University of Cambridge and Advanced Ceramics Limited (Stafford) as subcontractors. The project was initiated to continue with work started in 1995 under a DTI - LINK Collaborative Research Programme: Enhanced Engineering Materials "Enhancing the Properties of Bulk High Temperature Superconductors and their Potential Application as Fault Current Limiters". This project culminated with the testing of a full-scale 11kV prototype limiter in 1999. Fracture and burn-back of certain of the Bi-2212 elements used in the full-scale demonstrator had occurred and this was investigated prior to commencing the current project. It was concluded that: • Three-dimensional mathematical modelling of the quench process was required to optimise the design of the elements. No such model, which would need to calculate the evolution over time of thermal, electric and magnetic fields simultaneously had yet been developed in three dimensions. The modelling would need to work on volumetric elements of a small size to allow localised material characteristics to be incorporated to make provision for in-homogeneities of the characteristics of the superconducting material. • An improved method of testing elements following manufacture would be needed to maintain the critical current densities within acceptable limits. Modelling could be used to evaluate more precisely what the acceptable limits are. • Resistive shunting of each element was desirable to help prevent the development of localised quench sites leading to hot spots during operation. • Rapid cooling of the elements during initial immersion in the cryo-coolant had caused high levels of strain in the elements which were bonded to a substrate having a different thermal conductivity from that of the superconducting material. Precautions were required to prevent this. The investigation which yielded these conclusions was undertaken in 2001 at the expense of VA TECH T&D, in order to help to design a programme of work to optimise the design, manufacture, testing, handling and mounting of the superconducting elements. The programme was then used as the basis of a proposal to the DTI for a funded project which was initiated in December 2002 and completed in March 2004. The project, initially conceived with a twelve month timescale, was extended to fifteen months due to delays in the manufacture of the superconducting elements, which is still a difficult and labour-intensive process. It was decided also to iv incorporate other work to help to assess the feasibility of a practical distribution-scale Superconducting Fault-current Limiter (FCL). The additional uncertainties were: • The quantity of heat generated within and entering the cryo-enclosure would need to be better evaluated to assist with the design and costing of the enclosure and cooling provisions. This would depend on the element design and the arrangements for mounting and connection of the elements and the connection of the limiter structure to the external environment. Various options would need to be investigated. • The installation costs associated with placing an FCL in a substation would need to be estimated. • Target specifications for FCLs for various applications were required. This report presents the results of the investigations into the above areas. It also contains a detailed, carefully researched survey of the potential market for distribution-scale FCLs in the UK to form the basis of a business plan for commercialisation of the technology. The market study was funded by VA TECH T&D and was not included in the project proposal. Results An overview is given here of the results of investigations into each of the above areas of uncertainty: 3D Modelling program suite Modules were coded for input, calculation and output of numerical data. Graphical output of each aspect of interest is provided. The program suite is user interactive, enabling input data to be changed quickly and easily. Calculation speed depends on the number of volumetric elements defined within a given volume of material and has been found adequate for the purposes of this work. Results of the modelling have been confirmed in laboratory tests. Testing method and acceptance criteria Equipment for characterising the superconducting material is currently in use in the laboratory. Recommendations for adapting this to the factory environment are presented. A parallel programme of testing and modelling been used to determine the required accuracy of measurements to ensure stable quenching of series- connected superconducting elements. Resistive shunting Bi2212 elements with internal and external silver layers were designed, manufactured and tested. v Shunted elements of both types have been subjected to repeated quench cycles without degradation. Controlled Cooling Bi2212 elements have been cooled for a period of time, by immersion in gaseous nitrogen at marginally above the boiling point, prior to introducing nitrogen in the liquid phase. This is sufficient to prevent excessive strain in the material. Thermal Losses Extensive calculation of thermal losses for various arrangements has been carried out. These show that, whilst active cooling is desirable at modest levels of load current, the power consumption of the cooling equipment is within acceptable limits. Installation Costs These have been determined for the most likely initial application as bus-tie in a distribution substation at 11kV. FCL Specifications Rating requirements for a range of applications have been considered. Market Survey Published data detailing the plant ratings and local fault levels in most of the primary distribution substations in the UK were studied and it is concluded that there is an evolving need for action to prevent inadequate plant rating from becoming a problem for DNO's. Currently, around 10% of these locations will need switchgear upgrades or other action within a time period varying from months to a few years. The potential market size for FCLs has been evaluated on this basis. Conclusions By addressing all of the above issues, this work brings the concept of a fault-current limiter using high-temperature superconducting material in liquid nitrogen closer to practical implementation at full scale. The next logical step is to design, construct and test a unit for field-trial / demonstration in a distribution network. vi Acknowledgements Thanks are due to all of the many contributors, notably Dr. Bernhardt Zeimetz, Dr. Tim Coombes, Professor Archie Campbell, Professor Jan Evetts, Ahmed Kursumovic, Dr. Milan Majoros, Kartek Tadinada and Matthew Hills at Cambridge IRC and Materials Science; Dr. Peter Malkin, Paul Barnfather and Herbert Piereder at VA TECH T&D. vii Contents Page Executive Summary ii Introduction ii Results iii Conclusions iv Acknowledgements iv Final Report 1 1 INTRODUCTION 1 1.1 Technical Background 1 1.2 Aims and Objectives 1 1.3 Benefits 2 1.4 Programme of Work 2 2 COMPUTER MODELLING OF QUENCH PROCESS 4 2.1 Introduction 5 2.2 Computer Model 5 2.3 Results 7 2.3.1 Thermal instability 7 2.3.2 Dynamic Response 11 2.3.3 Observation of 'hot spots' 12 2.3.4 Current - Voltage scaling 14 2.4 Conclusions 15 3 COMPOUND ELEMENT 17 4 MULTI-ELEMENT MODEL 17 5 FCL DESIGN 18 5.1 Distribution Bus-coupler 18 5.2 Embedded Generator Connection 19 5.3 Larger Generator Connection 19 5.4 Hazardous Area Safety 19 5.5 Interconnection to Fault-prone Network 19 6 THERMAL LOSS EVALUATION 23 6.1 Introduction 23 6.2 AC losses in a single bar 23 6.3 AC Losses in several bars parallel to each other 24 6.4 AC losses in resistive joints 34 6.5 AC losses in currents leads 35 6.6 Cooling power 36 7 TEST EQUIPMENT AND SCHEDULE 38 7.1 Mounting 38 viii 7.2 Cooling 38 7.3 Electrical Supplies and Data Collection 38 7.4 Data Collection and Analysis 39 8 OPTIMISED ELEMENT 40 8.1 Introduction 40 8.2 V-I Characteristics 40 8.3 Single Element Simulation 41 8.4 Thermal Design 42 8.5 Homogeneity 43 8.6 Experiments 46 8.7 Conclusions 48 9 INSTALLED COST DATA 50 10 UK MARKET STUDY 51 11 PROJECT SUMMARY 51 Appendices Appendix 1 Development of Optimised Current Elements for a Resistive Fault Current Limiter - Stage I Programme: Evaluation of First Demonstrator ix 1 INTRODUCTION 1.1 Technical Background to the Project This project was initiated to continue with work started in 1995 under a DTI - LINK Collaborative Research Programme: Enhanced Engineering Materials "Enhancing the Properties of Bulk High Temperature Superconductors and their Potential Application as Fault Current Limiters". The LINK programme led to the development of a production process for bars made from high-temperature superconducting material (Bi-2212) which were incorporated in prototype Fault Current Limiters (FCLs).
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