SuperVARTM July 25, 2006 Edison Shrugged Things alter for the worse spontaneously, if they be not altered for the better designedly. DOE HTS Program Success: Enabling Commercial Rotating Machinery • AMSC builds on technology from DOE SPI program • 2005 – AMSC and TVA successfully demonstrate HTS synchronous condenser prototype • 2006 – AMSC expects to ship first commercial HTS synchronous condenser • 2003: AMSC delivers 5 MW HTS ship propulsion motor to U.S. Navy • First 1600 hp HTS industrial motor (1996-2000, DOE SPI – Rockwell, AMSC) • 2006: AMSC expects to deliver 36.5 MW ship propulsion motor to U.S. Navy in September 2006 • Candidate propulsion motor for DDX-class destroyers in 2010 and beyond “If I have seen a little further, it is by standing on the shoulders of Giants.” — Newton SuperVAR born with the question “What if ?” In 2001, American Superconductor management pitched their HTS product-line to TVA — including motors. TVA management asked AMSC what if a synchronous condenser was built using HTS technology? And so, the SuperVAR concept was born. “He that will not apply new remedies must expect new evils; for time is the greatest innovator.” — Bacon Steady State Benefits of HTS Rotating Machines Conventional Machine Limit, Overexcited Field Coil Heating (required field current is very high) Conventional Machine Limit, Underexcited Instability (field current goes to zero) Reactive Power Capability Curve, HTS, Low Synchronous Reactance Machine Synchronous Condensers Operate on This Axis Real Power SuperVAR VARS ( Per Unit) Additional VAR Capability of SuperVAR Device Absorbing VARS TM Generating VARS 1 Conventional Machine 1 Additional VAR Capability of SuperVAR Device 2 3 Field Current (Per Unit) • Low synchronous reactance design removes under-excited stability limit of conventional machines • Field current is well above zero at full rating under-excited • HTS field coils remove coil heating limit of conventional machines, • Full rating over-excited is possible • No thermal cycling of rotor coils yields improved machine life, no rotor rewinds projected Low synchronous reactance, HTS machines are capable of more reactive output than a conventional device for a given rating machine What Is A SuperVAR System? • A Synchronous Rotating Machine • Just like a large synchronous motor or generator • Armature and Support Equipment Conventional • Makes extensive use of off-the-shelf components and technologies • Rotating Field Winding Is Superconducting • • • • Field windings cooled to very low temperatures in a rotating Thermos bottle No thermal expansion/contraction degradation mechanisms No chemical degradation mechanisms (kept in a vacuum) Windings carry electricity without resistance • Controlled and Transient VAR/MW Provided to System • • • • Reactive power continuously adjustable (+/-12MVAR) 2X overload available for up to one minute Voltage regulation or reactive power compensation possible Transient MW/MVAR available (flicker, motor starting, other transients) Major SuperVAR Condenser Systems Refrigeration Systems Auxiliary Drive Motor 480V Service Exciter Stator and HTS Rotor 25 feet SuperVAR Condenser Technology Base • Leverages COTS (commercial off-theshelf) components • Stator – standard, air-cooled, iron core stator • 100 year old technology • • • • • Exciter Cooling components Ferro fluidic seal Conventional journal bearings Take advantage of technology base developed • • • AMSC 5000HP motor project 5MW Navy program PES, DVAR/DSMES SuperVAR condenser leverages conventional technology, demonstrated HTS machine features and other AMSC reactive power compensation products SuperVAR Condenser Prototype Specifications Rating 8 MVAR Voltage 13.8 kV line to line Ambient Temp -30o to +40oC Losses 1.7% rating at 8MVA Including 50kW 480V auxiliary power The SuperVAR condenser prototype has industrial class specifications Losses and Efficiency • Auxiliary loads measured • Losses at no load measured • 54.52 kW measured in factory test • Contract specification: 136kW 110 100 90 Efficiency( %) • System on-line, pony motor coasting, all other systems operating • 480V measured with true RMS clamp-on probe at site: 49kW • 480V measured in factory test with power analyzer: 46kW • Contract specification: 50kW 80 70 60 50 0 0.2 0.4 0.6 0.8 1 Output (p.u.) SuperVAR system auxiliary loads and losses meet contract specifications 1.2 1.4 SuperVAR Prototype Installation at Hoeganaes Corporation • Steel Mill • 45MVA arc furnace, 13.8kV load • Nearly continuous operation • Multiple large voltage transients per melt cycle • Many melt cycles per day • Gallatin Fossil Plant About 5 miles • • • • Four coal-fired generating units Construction was completed in 1959 Peak capacity is 988 MW Consumes about 7,400 tons of coal a day • About 5 miles from Hoeganaes • Machine Installed at Hoeganaes • Machine operating in conjunction with arc furnace SuperVAR prototype was operated in a demanding industrial application Prototype SuperVAR System Operation • Operation during over 2000 arc furnace melt cycles • Over 260 million pounds of steel melted • Equivalent to melting 90,000 Porsche Boxsters • Over 5 million load transients • 40 Porsche Boxters simultaneously accelerating from 0 to full power, 5 million times SuperVAR prototype was operated in a very challenging environment On-line Results 500 • Adjusted field current for overexcited and under-excited operation 140 300 120 250 100 200 80 150 60 100 40 50 20 0 0 200 400 600 800 1000 1200 1400 1600 0 1800 Time (secs) • +/- 8MVAR was demonstrated 20000 • Line voltages were slightly elevated 200 Vab Vbc ROTOR I(A) 18000 Voltage l-l (Vrms) and depressed as expected 160 350 180 16000 160 14000 140 12000 120 10000 100 8000 80 6000 60 4000 40 2000 20 0 0 200 400 600 800 1000 Time (secs) System was operated on-line to verify full +/- 8MVAR operation 1200 1400 1600 0 1800 Field Current (A) on-line Stator Currents (Arms) • Synchronized system and placed 400 180 Field Current (A) • Without arc furnace in operation 200 Ia Ib Ic ROTOR I(A) 450 On-line Transient Results • Machine successfully operated through extreme transients to support voltage 500 Ia 400 Ic • Reacts on the sub-cycle • Transient output observed in excess of machine rating • Significant real and reactive transient output observed • 10^6 to 10^7 major transients 300 200 Stator Currents (A) timescale Ib 100 0 -100 -200 -300 -400 -500 10.25 10.27 10.29 10.31 10.33 10.35 10.37 10.39 10.41 Time (secs) Results show dramatic, transient behavior providing support to furnace 10.43 10.45 On-line Results Total Measurement Period Voltage (03-21/22–2005) Hour 1 9pm – 3am Hour 2 Hour 3 ARC Furnace & Svar Current Svar Current SuperVar Online Voltage Hour 4 SuperVar Offline Hour 5 ARC Furnace & Svar Current Svar Current SuperVar Offline & Gallatin Bus-Tie Open Graph based on electrical data collected by TVA and EPRI Solutions during 03/21 and 03/22 Gallatin Test Hour 6 Cycle by Cycle Response of SuperVAR SuperVAR Terminal Voltage & Reactive Power 16 Supervar Produces more MVAR 14 15.5 13 MVAR 12 15 11 14.5 10 9 14 8 7 13.5 As Terminal Voltage Decreases 6 5 177.8 177.9 178 178.1 178.2 178.3 178.4 178.5 13 178.6 Time (Seconds) This characteristic of SuperVAR is beneficial in minimizing voltage fluctuation due to rapidly fluctuating loads such as arc furnaces Graph based on electrical data collected by TVA and EPRI Solutions during 03/21 and 03/22 Gallatin Test Terminal Voltage (kV) 15 What does it all mean? • Using appropriate statistical parameters, SuperVAR impact can be measured even though the condenser size is much smaller than the arc furnace and the Gallatin generators. • Reducing voltage/MVAR fluctuation at Hoeganaes results in a more stable arc and increases the operational efficiency of the arc furnace. • Reducing the voltage/MVAR fluctuation at Gallatin Steam Plant results in a more efficient operation of the generators. In theory there is no difference between theory and practice. In practice there is. — Dr. Y. Berra 489 Relay Event Log Data Data Peak 489 Data Logged to Date Note: Negative sequence current 70% Response to AF operation MVAR supplied 13 MVAR Response to AF operation MW supplied 11.7 MW Response to AF operation MVAR consumed 33.5 MVAR Response to cap bank switching Phase current 988 A RMS Response to cap bank switching Phase voltage 19,879 V RMS Response to cap bank switching • 489 Event Log captures alarm and trip parameters • Alarm events used to obtain a summary of machine response • Peak values measured are shown to the right SuperVAR system response of real AND reactive power noted of about 12 MVAR or 1.5 PU to arc furnace transients Flicker analysis by site recordings Independent analysis by EDF Waveform recorded during the tests “arc furnace + SuperVAR compensator” -Extract of line voltage waveform from raw binary file. - Sampling frequency: 6.4kHz With SuperVAR Pst = 8 to 9 - Flicker calculation by Flickermeter software: Pst during 10 min Conclusion: Flicker reduction is significant by using SuperVAR. Without SuperVAR Pst = 18 to 25 I compensator Flicker is the amplitude modulation of the fundamental frequency voltage by one or more frequencies. At some magnitudes, this modulation causes a visible brightening and dimming of lights connected to the modulated voltage, hence the term flicker. Summary Specifications of Production Units Incorporating Prototype Lessons Learned Specification Prototype Production Unit Notes Rating 8MVAR 12MVAR Rating achievable without major rotor design changes Transient 8PU 4PU Limit fault torques to those proven in prototype Excitation Speed 60 seconds 1 second 0 to full rating output for voltage collapse applications Mounting Trailer 2 Skids More secure mounting to withstand vibration, separate auxiliaries Cooling Neon Helium Simplify operations Controls Custom DVAR Derivative Simplify operations and maintenance Compressor Water cooled Air cooled Eliminate chiller to simplify operations Machine Type and Specifications Specifications • Synchronous Condenser • Superconducting field windings • Conventional armature • Exciter based on conventional components Specification Value Continuous Rating 12MVAR leading or lagging Overload Rating (≥1 minute) 24MVAR leading or lagging Transient Rating 12MVAR/MW to 50% sag Voltage 13.8kV Commanded Response Time ≤1 second (0 to rated MVA output) Physical Attributes Attributes Characteristic Synchronous Condenser Auxiliary Equipment Skid Length 20 feet 10 feet Width 8 feet 8 feet Height 8 feet 8 feet Weight 90,000 pounds 10,000 pounds SuperVAR Assemblies Will Be Delivered With Minimal Site Work Required Next stop: Russellville, Kentucky Logan Aluminum premier manufacturing facility with modern high-speed equipment, operational areas include ingot casting, hot rolling, cold rolling and finishing. Anything that won't sell, I don't want to invent. Its sale is proof of utility, and utility is success. — Edison T3 Contributes Significantly to Var Injection (Low Loading Condition) T1 Bank Var Usage 14,000 12,000 10,000 8,000 kVAR KVAR Lag KVAR Lead 6,000 4,000 T2 KVAR 16,000 2,000 14,000 78 155 232 309 386 463 540 617 694 771 848 925 1002 1079 1156 1233 1310 1387 1464 12,000 1/2 hour intervals in August 10,000 KVAR 1 KVAR Lag 8,000 KVAR Lead 6,000 4,000 2,000 1 80 159 238 317 396 475 554 633 712 791 870 949 1028 1107 1186 1265 1344 1423 1/2 Hour Intervals in August 2005 Sir Francis Drake, 1577 Disturb us, Lord, when We are too well pleased with ourselves, When our dreams have come true Because we dreamed too little, When we arrived safely Because we sailed too close to the shore. This R&D engineer’s prayer … naval pioneer and civil engineer, first captain to circumnavigate the Earth (1577-1580)