Capabilities of New US Manufacturing Facility for HV/EHV Solid Dielectric Cable Fahrudin Mekic Di Director, M Marketing k i and dS Sales l ABB Inc. Power Systems Division North America Overview © ABB Group April 18, 2012 | Slide 2 ABB cable system products Accessories and installation Cable project management Project Examples Overview © ABB Group April 18, 2012 | Slide 3 ABB cable system products Accessories and installation Cable project management Project Examples ABB’s production unit for HV cables Karlskrona, Sweden – submarine cables Huntersville, USA – land cables High Voltage Cables The world world’s s most modern cable factory Standard cables and advanced customized products E t d d and Extruded d paper insulated i l t d cables bl ffor b both th AC and d DC Submarine and underground high voltage turn key projects © ABB Group April 18, 2012 | Slide 4 ABB’s production unit for accessories Alingsås, Sweden – accessories Kabeldon Cable Accessories Joints, terminations and connections for power cables 1 - 420 kV. Tools and accessories. accessories Training programmes and supervision. © ABB Group April 18, 2012 | Slide 5 Background 1970s: Deliveries of extruded polymer insulated (“XLPE”) cable bl systems t for f voltage lt ratings ti up to t 145 kV. kV 1980s: XLPE transmission cable systems rated 230 kV. 1990s: XLPE transmission cable systems rated 420 kV and 500 kV. 1999: © ABB Group April 18, 2012 | Slide 6 polymer y insulated cable system y for The world’s first p direct current transmission. How much power with a pair of HVDC land cables? Power [MW] Aluminum conductor 1800 1600 1400 1200 1000 800 600 400 200 00 0 Station limit 80 kVdc © ABB Group April 18, 2012 | Slide 7 Copper conductor 150 kVdc 1800 1600 1400 1200 1000 800 600 400 200 0 Station limit 80 kVdc 320 kVdc Approximate data: depending on installation conditions 150 kVdc 320 kVdc … and with 1 system of HVAC land cables? Power [[MVA] Aluminum conductor Copper conductor 1600 1600 1400 1400 1200 1200 1000 1000 800 800 600 600 400 400 200 200 0 0 72.5 kVac © ABB Group April 18, 2012 | Slide 8 123 kVac 245 kVac 362 kVac 420 kVac Approximate data: depending on installation conditions 72.5 kVac 123 kVac 245 kVac 362 kVac 420 kVac Typical EHV AC Cable Design (Al Laminate Sheath) © ABB Group April 18, 2012 | Slide 9 RATED VOLTAGE 245 - 550 kV CONDUCTOR segmented Copper / round round, CONDUCTOR SHIELD Conductive PE (Borealis) INSULATION - Type - Material - Supplier Triple extruded, dry cured XLPE Borealis INSULATION SHIELD Conductive PE (Borealis) LONGITUDINAL WATER SEALING Swell able tape METALLIC SCREEN Copper wire TEMPERATURE MONITORING FIMT in metallic screen RADIAL WATER SEALING Laminate (Al ) and PE OUTER JACKET Polyethylene D Development l off P Polymer l IInsulated l d HVDC C Cables bl 1999 G Gotland 160 kV (±80 kV) 50 MW 43 miles 2000 Direct Link 160 kV (±80 kV) 3×60 MW 3×40 miles © ABB Group April 18, 2012 | Slide 10 2002 Murray Link 300 kV (±150 kV), 220 MW 112 miles 2007-2009 Type and PQ Q test 2 2500 mm Cu or Al 640 kV (±320 kV), up to 1100 MW 2002 C Cross S Sound d 300 kV (±150 kV), 330 MW 26 miles subsea 2013 D lWi 1 DolWin1 640 kV (±320 kV), 800 MW 60 miles (+47 miles subsea) 2006 E tLi k EstLink 300 kV (±150 kV), 350 MW 20 miles (+46 miles subsea) 2015 N dB lt NordBalt 600 kV (±300 kV), 700 MW 31 miles (+248 miles subsea) 2009 B Wi BorWin 300 kV (±150 kV), 400 MW 47 miles (+80 miles subsea) 2015 D lWi 2 DolWin 640 kV (±320 kV), 900 MW 56 miles (+28 miles subsea) 2012 EWIP 400 kV (±200 kV), 500 MW 46 miles (+116 miles subsea) In progress T Type and d PQ test t t 2 2500 mm Cu or Al 1000 kV (±500 kV), up to 1700 MW Typical HVDC Underground Cable Design © ABB Group April 18, 2012 | Slide 11 Conductor material Copper or Aluminum Conductor screen material Conductive PE Insulation type/material Dry cured HVDC polymer (XLPE) Insulation screen Conductive PE Bedding g Conductive swelling g tapes p Metallic screen Copper wires Bedding Conductive swelling tapes Radial moisture barrier Aluminum-PE laminate Outer jacket Polyethylene Overview © ABB Group April 18, 2012 | Slide 12 ABB cable system products Accessories and installation Cable project management Project Examples ABB Power Products Cable accessories, accessories 12 – 420 kV ABB AB, Kabeldon, Sweden Full range of cable accessories from 12 to 420 kV Extensive reference list from installations worlwide since 40 years Standard products on pricelist Quotations for any projects 12 24 36 Medium Voltage © ABB Group April 18, 2012 | Slide 13 42 52 72 84 123 High Voltage 145 170 245 300 Extra High Voltage NB ! Pictures not in scale 362 420 kV Well qualified according to standards – HVAC… Prequalification tests Qualifying the technology and the manufacturer Type tests Qualifying the product and the project © ABB Group April 18, 2012 | Slide 14 … as well as for HVDC Light © ABB Group April 18, 2012 | Slide 15 Complete supplier for cable system solutions © ABB Group April 18, 2012 | Slide 16 System studies and system design Project management Manufacturing and delivery of cables Procurement of other components Civil works Installation Supervision Testing Recovery of old cables Maintenance of fluid-filled cable systems S i agreements Service t Installation services © ABB Group April 18, 2012 | Slide 17 Survey Supervision Cable laying Erection and jointing Testing g after installation Turn-key responsibility Fault location if a damage occur Repair of cable faults ABB Power Cables Service Service Portfolio © ABB Group April 18, 2012 | Slide 18 Manufacturing and delivery of spare cables & accessories Service & Repair preparedness agreements On Call 24/7 Support Maintenance of cable system Storage and handle of strategic spare material t i l & equipment i t As Built documentation Overview © ABB Group April 18, 2012 | Slide 19 ABB cable system products Accessories and installation Cable project management Project Examples Complete project responsibility (1/3) Planning Route surveys System studies Typography Cable optimization Geological Environmental study Geothermal D Documentation i Design g and engineering g g © ABB Group April 18, 2012 | Slide 20 Cable design Route design Development p testing g Type testing Complete project responsibility (2/3) Manufacture Cable Cable accessories Installation tools Trenching © ABB Group April 18, 2012 | Slide 21 Transportation and installation Size and weight of cable reels Length of cable sections Jointing Drilling Power cable Plowing Fiber optic cable Rock cutting Blasting Complete project responsibility (3/3) Installation of accessories Joints Terminations Oil feeding system (LPOF cables) Surge arresters Link boxes Mechanical protection Burial Concrete slabs Pipes Repair preparedness Field testing © ABB Group April 18, 2012 | Slide 22 HVDC test Provide spare parts HVAC test Provide specialists Overview © ABB Group April 18, 2012 | Slide 23 ABB cable system products Accessories and installation Cable project management Project Examples Overview of Offshore Wind Interconnection System Offshore wind turbines Offshore AC substation platform(s) Offshore HVDC converter Onshore HVDC converter DC cable bl system t AC MV cable system AC HV cable system 100 - 300 MW: 300 - 500 MW: 500 - 1000 MW: © ABB Group April 18, 2012 | Slide 24 160 kV ((±80 kV)) HVDC 300 kV - 400 kV (±150 kV - ±200 kV) HVDC 640 kV (±320 kV) HVDC Onshore AC network BorWin 1 HVDC Transmission System – Cable Designs North Sea segment (75 miles) 1200 mm2 Cu Wadden Sea segment (5 miles) 1600 mm2 Cu Underground segment (47 miles) 2300 mm2 Al © ABB Group April 18, 2012 | Slide 25 BEC Submarine Cable Project Overview Circuit Route is approximately 6.4 miles between Bayonne, NJ d B kl NY NJ and Brooklyn, NY Cable route was selected based on many factors including llocation relative to numerous anchorage areas and ti l ti t h d shipping channels in New York Harbor, and permitting requirements for Army Corp and the states of New York i t f A C d th t t fN Y k and New Jersey Th Three cables installed bl i t ll d Burial depth of 4 Burial depth of 4‐‐15 ft Phase separation of 25‐ Ph Phase separation of 25 ti f 25‐33ft Water depth up to 70ft © ABB Group April 18, 2012 | Slide 26