Customer acceptance of high temperature superconducting (HTS) cable technology requires a substantial field demonstration illustrating both the system's technical capabilities and its suitability for installation and operation within the utility environment. In this project, the world's first underground installation of an HTS cable using existing ductwork, a 120 meter demonstration cable circuit was designed and installed between the 24 kV bus distribution bus and a 120 kV-24 kV transformer at Detroit Edison's Frisbie substation. The system incorporated cables, accessories, a refrigeration system, and control instrumentation. Although the system was never put in operation because of problems with leaks in the cryostat, the project significantly advanced the state-of-the-art in the design and implementation of Warm Dielectric cable systems in substation applications. Lesson learned in this project are already being incorporated in several ongoing demonstration projects. iv v
PRODUCT DESCRIPTIONFollowing up the successful testing of a complete 50 m, 115 kV High Temperature Superconducting (HTS) power cable system prototype, EPRI, Pirelli Power Cables and Systems, the Department of Energy, Detroit Edison, and American Superconductor Corporation undertook a project to design, install, and operate a 24 kV HTS power cable at Detroit Edison's Frisbie substation to serve customer load. The demonstration cable circuit ran approximately 120 m between the 24 kV bus distribution bus and a 120 kV-24 kV transformer. Because of problems with leaks, the cable system was never put in continuous operation, but the lessons learned during this ambitious project significantly advanced understanding of critical technical and managerial issues and will directly impact future development efforts, some of which are already underway. This report summarizes all activities and lessons learned from this demonstration program from its inception in 1998 to December 2003.
Results & FindingsAs designed, the demonstration system incorporated cables, accessories, a refrigeration system, and control instrumentation. In the course of the project:• 29, 000 meters of high strength superconducting tape were manufactured and tested. The mechanical characteristics of the balloon-proof tape withstood the rigors of cable manufacturing and installation. Robust tape enables optimized cable conductor designs and tight cable bending radii and is vital to practical application of HTS power cables.• A process was developed and demonstrated for the manufacture of long-length Warm Dielectric (WD) HTS power cables. The long conductor assembly demonstrated the fabrication techniques that could eventually be used for manufacturing of commercial lengths of cable. Factory tests to applicable cable standards confirmed that the dielectric insulation had been properly extruded and that the underlying layers had kept their integrity.• Pre-molded accessories were designed, tested and installed for WD HTS cables. One of the lessons learned in this project was that ...
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