Alternating Current Loss Measurement of Power Cable

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Alternating Current Loss Measurement of Power Cable ALTERNATINGCURRENTLOSSMEASUREMENTOFPOWER CABLECONDUCTORSWITHLARGECROSSSECTIONSUSING ELECTRICALMETHODS vorgelegt von Master of Science René Suchantke geboren in Berlin von der Fakultät IV - Elektrotechnik und Informatik der Technischen Universität Berlin zur Erlangung des akademischen Grades Doktor der Ingenieurwissenschaften - Dr.-Ing. - genehmigte Dissertation Promotionsausschuss: Vorsitzender: Prof. Dr.-Ing. Kai Strunz Gutachter: Prof. Dr.-Ing. Ronald Plath Gutachter: Prof. Dr.-Ing. Steffen Großmann Gutachter: Prof. Dr.-Ing. Rolf Schuhmann Tag der wissenschaftlichen Aussprache: 13. Juli 2018 Berlin 2018 René Suchantke: Alternating Current Loss Measurement of Power Cable Conduc- tors with Large Cross Sections Using Electrical Methods © July 2018 Dedicated to my beloved wife and biggest critic Isabell. You, the people, have the power, the power to create machines, the power to create happiness! You, the people, have the power to make this life free and beautiful, to make this life a wonderful adventure. [...] Let us fight for a world of reason, a world where science and progress will lead to all men’s happiness. Charlie Chaplin ABSTRACT High voltage power cables for bulk AC power transport use the Milliken conductor design from a certain cross section up to decrease transmission losses. It is not possible to reliably assess their AC losses by simulation or other calculation methods in advance, as the performance of this complex design strongly depends on manufacturing processes and quality. The exact knowledge of the AC resistance is important, because it is a critical design parameter for the thermal dimensioning of the cable and whole cable systems. Therefore, it is necessary to accurately determine the AC losses by measurement using the electrical or the calorimetric method. This work focuses on the electrical method solely, as it can be performed much faster with less logistical effort. The goal is to have a measurement setup, where the measured losses are as close as possible to the true losses. The true losses result in conductor heating, which limits the transmission power. They are also called Joule losses. Theoretical calculations, FEM simulations in Comsol Multiphysics and mea- surements have been used in combination to evaluate different, possible influences in AC resistance measurements. After the problem definition and the presentation of the methodology, past advances and concepts focusing on AC resistance determination were shown. Then, after the basics were made clear to the reader, the measurement circuit was defined and different error sources in measurement setups were evaluated. These included the influence of the sheath and return conductor position upon true and measured losses, the influence of current homogenization and placement of voltage tap-offs. A recommendation for the preparation, setup and measurement procedure was given. At the end, multiple Milliken conductors were measured using the proposed method and compared to the IEC standard. It was shown that the electrical measurement method is able to measure the true AC losses of complex conductors consisting of insulated wires. One important requirement is that the voltage pick-up loop is large enough to capture enough complex magnetic field originating from the conductor under test. On the other side, complex magnetic fields caused by eddy currents in adjacent conductors should not be captured by the pick-up loop as they also affect the measured losses. Using 2 equally spaced return conductors in the same plane as the conductor under test and the average of at least 4 evenly distributed voltage pick-up loops located at the surface of the insulation of the cable, will deliver results of sufficient accuracy. The findings of this thesis indicate that great care must be taken for multiple aspects in the AC resistance measurement of complex conductors. Engineers performing AC resistance measurements have to be aware of error sources, specifically the interplay between conductor positions and apparent losses. The electrical measurement method needs to be thoroughly prepared, espe- cially regarding the contacting of current path and voltage tap-offs. Never- theless, the effort concerning time and logistics is still significantly smaller compared to a calorimetric measurement. ZUSAMMENFASSUNG Hochspannungskabel für die Übertragung großer Mengen elektrischer Energie verwenden ab einem bestimmten Querschnitt die Millikenleiter- Bauweise zur Senkung der Wechselstromverluste. Es ist nicht möglich, die Verluste dieser komplexen Leiter verlässlich vorab zu berechnen, da die Performance dieses Leiterdesigns unter anderem stark von Einflüssen der Fertigung abhängt. Eine genaue Kenntnis der Wechselstromverluste ist allerdings zwingend notwendig, da diese zur thermischen Dimensionie- rung des Kabels und ganzer Kabelsysteme genutzt werden. Es ist daher erforderlich, die Verluste durch Messungen zu bestimmen. Zur Auswahl stehen die elektrische und die kalorimetrische Messmethode, wobei sich diese Arbeit exklusiv auf erstere fokussiert. Diese ermöglicht eine schnellere Messung der Verluste mit geringerem logistischen Aufwand. Das Ziel jeder Messung sollte sein, dass die Diskrepanz zwischen gemessenen und den echten Wechselstromverlusten des Innenleiters so gering wie möglich ist. Die echten Verluste sind unbekannt und tragen in Betrieb maßgeblich zur Erwärmung des Innenleiters bei, was gleichzeitig die Übertragungsverluste des Kabels senkt. Um verschiedene mögliche Einflüsse in Wechselstromwiderstandsmessun- gen zu evaluieren, wurden Theorie, FEM Simulationen in Comsol Multiphysics und Messungen in Kombination eingesetzt. Nach der Definition des Pro- blems und des Ziels wurde die Methodik vorgestellt. Anschließend wurden relevante Konzepte zur Ermittlung von Wechselstromverlusten aufgezeigt. Darauf folgt die Definition des Messaufbaus und das Herausstellen rele- vanter Einflüsse auf die Messungen. Als am relevantesten stellten sich der Einfluss von Kabelschirm und Rückleiter auf die gemessenen und echten Verluste des Kabels heraus. Hinzu kommt ein signifikanter Einfluss der Stromhomogenisierung und der Positionierung der Spannungsabgriffe auf dem Leiter. Danach wurde eine Empfehlung für die Vorbereitung, den Aufbau und die Durchführung der Messung gegeben. Am Ende wurden verschiedene Millikenleiter-Designs mit den vorgeschlagenen Methoden vermessen und mit der aktuellen IEC Norm verglichen. Die Untersuchungen haben gezeigt, dass die elektrische Methode unter gewissen Voraussetzungen dazu im Stande ist, die echten Wechselstrom- verluste von komplexen Leitern mit isolierten Einzeldrähten zu messen. Eine Anforderung ist beispielsweise, dass die Spannungsmessschleife groß genug ist, um komplexe Magnetfelder, die vom zu untersuchenden Leiter erzeugt werden, einzufangen. Allerdings darf die Messschleife nicht so groß sein, dass andere komplexe Magnetfelder, erzeugt von Wirbelströmen in umgebenden Leitern, in die Messschleife einkoppeln. Diese können die gemessenen Verluste sonst direkt beeinflussen. Der empfohlene Aufbau zur Messung der Wechselstromverluste von Millikenleitern verwendet 2 äquidi- stant platzierte Rückleiter, die in einer Ebene mit dem zu untersuchenden Leiter liegen. Die Messung der Spannung erfolgt aus dem Mittelwert von mindestens 4, gleichmäßig um die Oberfläche der Isolation des Kabels verteilten, Spannungsmessschleifen. Die Analyse des Problems hat gezeigt, dass die Wechselstromverlustmes- sung von komplexen Leitern genauer Kenntnisse über mögliche Störeinflüs- se bedarf. Die Auswirkung der Positionierung der Leiter auf die gemessenen Verluste sollten vom Anwender verstanden sein und in der Versuchsvor- bereitung und Ausführung weitestgehend eliminiert werden. Auch für die elektrische Methode müssen daher einige Maßnahmen und Vorbereitungen — insbesondere hinsichtlich der Kontaktierung der Spannungsabgriffe und Strompfadkontaktierung — zur akkuraten Messung getroffen werden. Im Vergleich zur kalorimetrischen Methode sind diese vorbereitenden Maßnah- men allerdings wesentlich weniger zeitintensiv. PUBLICATIONS It takes many good deeds to build a good reputation, and only one bad one to lose it. Benjamin Franklin In the following, publications related to the topic of this thesis are listed, where the author took direct part during his research activity at Technische Universität Berlin: [CIG18] CIGRE, ed. Basic principles and practical methods to measure the AC and DC resistance of conductors of power cables and overhead lines. D1.54. CIGRE, 2018. [Sch+14] Gero Schröder, René Suchantke, Hendrik Just, Rolf Schuhmann, and Ronald Plath. “Maßnahmen zur Reduzierung des Skin- Effekts bei Energiekabeln durch optimierte Leiterkonstruktio- nen und deren messtechnische Bewertung.” In: Diagnostik elek- trischer Betriebsmittel 2014. ETG-Fachbericht. Berlin u.a.: VDE- Verl., 2014. isbn: 978-3-8007-3648-5. [Sch+15] Gero Schröder, Volker Waschk, Ronald Plath, Rolf Schuhmann, and René Suchantke. “Measures to reduce skin-effect losses in power cables with optimized conductor design and their evalu- ation by measurement.” In: Jicable 2015 - 9th International Confer- ence on Insulated Power Cables. Paris, France, 2015. [SPS16] René Suchantke, Ronald Plath, and Rolf Schuhmann. “Beson- derheiten bei der Messung von Wechselstromwiderständen von kurzen Leitern und kurzen Kabelstücken mit großen Quer- schnitten: Difficulties with AC resistance measurements of short conductor- and cable samples with large cross-sections.” In: VDE-Hochspannungstechnik 2016. ETG-Fachbericht. Berlin: VDE- Verlag,
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