resilient multi-terminal hvdc networks with high-voltage ...resilient multi-terminal hvdc networks...
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Resilient Multi-Terminal HVDC Networks
with High-Voltage High-Frequency
Electronics
Dr Rob Sellick
High Voltage Lab Manager, GE Global Research
January 14, 2015
Award No. DE-AR0000224
GE Global
Research
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GE Global
Research
Project Objectives
1
‣ Overall goal: Develop components, architecture and
controls for fault-resilient multi-terminal DC power system
– Multi-terminal system, and DC/DC transformer
‣ Decrease cost and complexity and losses
– Reduce number of components and conversions
‣ Published DC/DC transformers with AC stage up to 500Hz
– GE project using 20kHz, to reduce physical size
‣ Performance metrics:
– Losses, overall system cost
‣ Universities’ focus on system-level for wind and solar
applications
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GE Global
Research
System Diagram
2
Isolator
780 V DC
780 V DC
10 kV DC
480 V ac feeder
600 V DC
10kV 100kW dc/dc
transformer
100kW load bank
Commercial dc/dc
supply
1
2
3
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GE Global
Research
2014 Achievements
3
‣ 300kV DC offset voltage, with 2 x
250kVA on DC/DC transformer
– Discrepancy between design
and as-built transformer
– Difficulties with 300kV cable
connector into tank
‣ Demonstration of MTDC system
and control performance –12
modules, 10kV/600V, 100kW
– Complexity to control series-
connected devices
– Simulation and HIL
implementations by Universities
Final Year
Accomplishments
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GE Global
Research
Project Achievements
4
‣ Successful demonstration of system architecture and
enabling technologies
– Understanding working multi-terminal control system
– Improved understanding of transformer design to
consider 3-D modelling
‣ Remaining challenges:
– Long-term impact of high-frequency stress on insulation
– Packaging for scalability into system-level HVDC DC/DC
transformer
– Performance under actual fault conditions
Overall Project
Accomplishments
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GE Global
Research
Technology-to-Market
‣ Ultimate objective: Transition to a GE business
‣ Several potential markets
– Subsea, Marine, Renewables (Solar, Wind), Utilities
‣ Difficulty in validating costs
– CAPEX
– OPEX
– Installation
– Maintenance
– Disposal
5
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GE Global
Research
Post ARPA-E Goals
‣ GE internal program to
build on this work
‣ Remaining technical
challenges:
– Packaging for reliability
and maintainability
– Long-term high-
frequency stress on
insulation
– Field demonstration
6
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GE Global
Research
Conclusions
‣Working practical
demonstrations for multi-
terminal network and DC/DC
transformer
– Enhanced understanding
of transformer design and
construction
– Assisted development of
300kV connector supplier
– Identified risks to be
addressed in next phase
of development
7
‣Within GE, established core
multi-disciplinary team
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Nanoclay Reinforced Ethylene-
Propylene-Rubber for Low-Cost HVDC
Cabling
Dr Qin Chen
Electrical Engineer
January 14, 2015
Award No. DE-AR0000231
GE Global
Research
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GE Global
Research
Project Objectives
‣ Overall goal: Develop new,
low-cost insulation for high-
voltage direct current (HVDC)
electricity transmission cables.
– New insulation by embedding
nano-materials into specialty
rubber
‣ Decrease system-level cost
– Increase power density
– Decrease manufacture time
and cost
9
Extruded cable
with uniform
structure
Lapped cable
with multilayer
structure
State of the art
http://en.wikipedia.org/wiki/File:HVDC_Submarine_Cable_Cross
_Section_-_from_New_Zealand_Inter-island_scheme.jpg
http://upload.wikimedia.org/wikipedia/commons/8/8
2/Hochspannungskabel_110kV_400kV.JPG
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GE Global
Research
DC Nanoclay-EPR: Experimental
10
Polymer (EPR) resin Nanoclay filler Compounded material
Mix with
additives
Sheet samples for electrical testing Melt press,
crosslink
EPR: ethylene-propylene-rubber;
XLPE: crosslinked polyethylene
More than 30
compositions studied,
with different filler
types, loadings,
surface treatments
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GE Global
Research
2014 Achievements
‣ 50kV DC cable prototype
successfully extruded using AC
EPR cable fabrication process
– DC nanoclay-EPR insulation
(345 mil), copper conductor
(107 mm2)
‣ Promising lab test results
‣ 160kV breakdown
– QA test, space charge
‣ Endurance testing ongoing
– 92.5kV, no breakdown
11
Final Year
Accomplishments
DC XLPE after degasing (80°C, 5 days)
N-EPR, without degasing
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GE Global
Research
Remaining challenges
‣ Better understanding of the
role of nanoclay morphology
& electrical properties on
DC conduction and space
charge behavior
‣ Standard qualification test
for the cable prototype
12
16.5 kV/mm field; 60°C with 2°C/mm
gradient (anode cold)
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GE Global
Research
Project Achievements
‣ Novel type of nanoclay reinforced Ethylene-Propylene-
Rubber (EPR) has been developed, aiming at achieving
layered structure in an extruded insulation
‣ Good HVDC performance and wide applicability
– More than 30 compositions studied, with different filler
types, loadings, surface treatments
– Compromise between breakdown shape factor, thermal
conductivity and relaxation time constant
13
Overall Project
Accomplishments
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GE Global
Research
Technology-to-Market
‣ Ultimate goal: Leverage new insulation material to reduce
overall HVDC system costs
‣ Developed partnership with cable manufacturers
– Ongoing discussions about potential JV / licensing
opportunities with possible partners
‣ Accessory development required
‣ Field trial required
– Conservative customers
14
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GE Global
Research
Conclusions
‣ Significant technical progress
with prototype at meaningful
voltage level (50kV DC)
‣ Established key relationship
with cable manufacturer
‣ Initial indications of good
commercial viability
15
Novel DC Nanoclay-EPR
• AC nanoclay-EPR is a
mature technology
• Design for DC:
morphology, electrical
property
• Extruded cable with layered
structure