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200 Kv DC Extruded Cables Crossing the San Francisco Bay

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200 Kv DC Extruded Cables Crossing the San Francisco Bay 21, rue d’Artois, F-75008 PARIS B1_105_2010 CIGRE 2010 http : //www.cigre.org 200 kV DC extruded cables crossing the San Francisco Bay M. BACCHINI T. WESTERWELLER N. KELLEY R. GRAMPA (*) Siemens, Prysmian Power Cables M. MARELLI Germany and Systems, Prysmian Powerlink, Italy U.S.A. SUMMARY In the Bay of San Francisco, in California, there is the first case in the world of commercial transmission of electrical energy in direct current at 200 kV with Multilevel VSC technology and cables with extruded insulation: it is the “Trans Bay Cable” (TBC) project. The innovative submarine HVDC link consists of two cables in bipolar configuration and has the capability to transmit 400 MW over a length of 55 miles i.e. 88 km. The connection between converter station in Potrero - in San Francisco - and Pittsburg - in the East Bay - allows the closure of the loop of the already existing “Greater Bay Area” transmission system, thus reinforcing the power flow directed to the center of San Francisco. This will decrease transmission grid congestion in the East Bay and will also avoid the need of building additional power plants in the City of San Francisco. Cables are manufactured by Prysmian in a factory close to Naples, in Italy, which is fully dedicated to submarine cables. Design for this specific project includes a copper conductor with a cross section of 1100 mm2, extruded insulation, lead sheath and armour of steel wires. The two HVDC cables (+/- 200 kV) are laid in bundle and buried at a depth of 6 ft (1.8 m), in a safe corridor separate from any existing AC cables. Laying operations are carried out by two different vessels: the “Giulio Verne” (one of the largest cableships in the world) for most of the route and a suitably equipped barge for the very shallow waters in the East Bay. The use of extruded insulation cables in the HVDC links showed a large increase during last years, due to some advantages that polymeric insulation can offer in comparison to traditional laminated mass impregnated cables and since the large technological progress happened, which involved materials, manufacturing process, system integration. KEYWORDS HVDC – VSC – Submarine cable – Extruded Cable – Multilevel converter – Interconnection. (*) Corresponding author Renato Grampa [[email protected]] PROJECT BACKGROUND The Trans Bay Cable Project (TBC Project) is a 400 MW, ±200 kV, submarine-based, point-to-point, DC transmission system which transmits power from the generation resource-rich area of Pittsburg, California to the City and County of San Francisco load-pocket (as shown in Figure X). The Project was developed by Trans Bay Cable, LLC and it will be owned by the Pittsburg Power Company upon Commercial Operation. Extruded DC and AC cable systems were provided by Prysmian and voltage-source DC converter stations were provided by Siemens as consortium partners under an engineer-procure-construct (EPC) contract. Commercial Operation is expected to be achieved during the first quarter of 2010. The benefits of the Project are many. The electric capacity and energy delivered by the Project to the City and County of San Francisco load-pocket improves power supply reliability and provides for future load-growth needs. In addition, overall electric system losses are substantially reduced. This focus of this paper is the 200 kV extruded DC submarine cable technology and installation provided by Prysmian. PROJECT DESCRIPTION AND INTERFACES The Project is integrated into the California ISO Control Area and interconnects with the Pacific Gas & Electric (PG&E) Pittsburg 230 kV Substation in Pittsburg, California and the PG&E Potrero 115 kV Substation in San. Francisco, California. A basic scheme of the link is reported in Figure 1. a.c. d.c. a.c. transmission transmission transmission 115 kV 200 kV 230 kV Fig. 1 Basic layout of the whole connection Specifically, the Project components include the: Pittsburg 230 kV Extruded AC Cable System which interconnects the Pittsburg Converter Station with the PG&E System at the PG&E Pittsburg Substation; Pittsburg Converter Station based upon Siemens’ Modular Multi-level Converter HVDC Plus Converter Technology; Land and Submarine ±200 kV Extruded DC Cable Technology which interconnects the Pittsburg Converter Station with the Potrero Converter Station; Potrero Converter Station based upon Siemens’ Modular Multi-level Converter HVDC Plus Converter Technology; and Potrero 115 kV Extruded AC Cable System which interconnects the Potrero Converter Station with the PG&E System at the PG&E Potrero Substation. 1 HVDC SYSTEM AND PLUS TECHNOLOGY A new modular multilevel converter (MMC) topology has been introduced by Siemens into HVDC applications during recent years. The concept of this topology is based on the converter arms acting as controllable voltage sources with a high number of possible discrete voltage steps. This allows for forming an approximate sine wave in terms of adjustable magnitude of the voltage to the AC terminal. This principle is shown in Figure 2. Each of these variable voltage sources is designed with a number of identical but individually controllable sub-modules. Each sub-module is a two-terminal component which can be switched Fig. 2 - Converter in Modular Multilevel topology and control principle between a state with full module voltage and a state with zero module voltage in both current directions. Dependent on the current direction, the capacitor can be charged or discharged. Besides auxiliary components and electronics, each sub-module consists of an IGBT half bridge and a capacitor unit. By serially connecting many modules an +U /2 d elegant multilevel topology can be constructed. It is possible to individually and selectively control each of the individual sub-modules in a converter arm. The total voltage of the two converter arms in one phase unit equals the DC voltage, and by adjusting the ratio of the converter arm voltages in one phase -Ud/2 module, the desired sinusoidal voltage at the AC terminal can be achieved. See Fig. 3 - AC and DC Voltages controlled by Converter Module Voltages Figure 3. DEVELOPMENT OF EXTRUDED CABLES FOR HVDC TRANSMISSION The TBC Project makes use of a new generation of HVDC cables, which are insulated with an extruded synthetic compound. If compared to traditional mass impregnated or oil filled cables, extruded cables generally provide several advantages. For DC application, they comprise use of simpler manufacturing technologies, a lower production cost, and possibility to operate cables at higher temperature than mass impregnated. These facts have been the main drivers which led to a large increase of the use of extruded insulation cables in the HVDC links during last years. Prysmian’s first stages of research was done at the end of years ‘90s on several polymeric insulating materials and included life test under increasing electrical stress, definition of coefficient of life (N, defined by using the very well known Weibull distribution law), investigation of space charge 2 distribution by applying PEA technology (Pulsed Electroacustic Analysis) to flat models of different polymeric insulating materials. Electrical conductivity of polymeric materials was investigated as well, by using flat models at different temperatures and electrical stresses. The second part of the study was done on model cables, insulated with most promising materials; the extensive test program consisted of: - d.c. dielectric strength, cold and hot conditions (from 20 to 90°C); - L.I. test (cold and hot) and L.I. superimposed onto HVDC of opposite polarity (cold and hot) - HVDC life test with step voltage increasing up to breakdown, with thermal cycles at 70°C; - HVDC life test as above, with daily polarity reversals. Eventually, the third part of the development project considered the best combination of semi- conductive and insulating materials. A full-size 200 kV 630 mm² cable and relevant accessories (flexible factory and repair joint, rigid repair joint, terminations) was submitted to a long-term test, following recommendation included in Cigré Technical Brochure 219 for DC VSC cable systems. The knowledge acquired during previous years and the very positive outcome of all development tests suggested to continue with development of HVDC extruded cables and a further pre-qualification started at increased voltage. A test protocol was prepared and implemented to allow a full qualification with and without polarity reversal, thus allowing use of DC extruded cables for both LCC and VSC converter technologies. Full system, including cable and accessories, has been subject to the following voltages, with thermal cycles in accordance to mentioned Cigré TB 219: - VSC System, U0 = 300 kV: o Voltage Cycle test: 435 kV, 70°C o Up2,S = 640 kV o Up2,O = 360 kV - LCC System, U0 = 250 kV: o Voltage Cycle test: 365 kV, 70°C o Polarity reversal: 315 kV, 70°C o Up1 = 500 kV (impulse superposed to DC at opposite polarity) Full test was successfully completed thus confirming that the applied materials and technology are fit for use for HVDC transmission: Additionally it further proved the importance of extensive development programs to move towards to industrial application with reasonable confidence. CABLE MANUFACTURING AND TESTING The most significant cable part of the TBC Project is the ±200 kV DC submarine cable. The power rating of the connection is 400 MW, which is considered as increased by 5% at sending point thus giving a nominal rated current of 1050 A. Specific environmental and installation conditions led to design a copper conductor size of 1100 mm2, which is of a compacted circular design, constructed from annealed plain copper wires and filled with water blocking compound to limit water propagation in case of cable severance. The insulation system consists of an inner semi-conducting screen layer, the insulation compound and an outer semi-conducting insulation screen, extruded simultaneously. The insulation is composed of a cross-linked polyethylene suitable for HVDC application.
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