3. HVDC Cables 2

© ABB Group Slide 1PowDoc id

HVDC Cable SystemsUnderground and Subsea

Kristian Bergman, Power Systems Division North America – October 25, 2011

Agenda

� HVDC Cable Systems

� Producing HVDC Cables

� Installing HVDC Cables

� Reliability

� HVDC – History and Reference Projects

Grid Systems offerings

HVDC (LCC)� Bulk power transmission – (OHTL)� Long sea transmission – (Cable)� Asynchronous connections – (Back-to-Back)

HVDC Light® (VSC)� Underground and sea-cable transmission� Connecting wind and solar energy to grid� Off-Shore applications

FACTS - Series Compensation/ Shunt Compensation� Increased transmission capacity� Power Quality

High voltage cables� Underground and submarine AC and DC transmission

Semiconductors� Thyristors and IGBTs

Consulting � Transmission system planning� System studies and optimized system sizing and design

After Sales Service and Support � System Upgrades/ Life extension� Parts, Maintenance & Support

HVDC CABLE SYSTEMS

Characteristics of HVDC Transmission

� Controllable - power injected where needed

� Facilitates integration of remote diverse resources with less impact on existing grid

� Higher power, fewer lines

� Less expensive lines

� No stability distance limitation

� Reactive power demand limited to terminals independent of distance

� Lower losses

� No limit to underground or sea cable length

� Asynchronous, ‘firewall’ against cascading outages

Solid Dielectric Cables for High Voltage Transmission SystemsCharacteristics:

� Absence of insulating fluids eliminates the risk of accidental release of hazardous materials and substances into the environment;

� Lower maintenance costs (solid dielectric cablesare virtually maintenance free);

� Cable capacitance per mile and phase is less than 60% of the capacitance of fluid filled cables;

� Ability to splice cables in discontinuous shifts. (important characteristic when cable circuits are installed in public roads since it permitstemporary suspension of splicing during morning and afternoon rush hour traffic).

� Cables are suitable for direct burial in opentrenches at a lower overall installation cost thanusing concrete encased duct bank systems;

Typical Underground Cable – Up to 640 kV (±320 kV) DC

Conductor material: Copper or Aluminum

Conductor screen material: Conductive PE

Insulation type/material: Dry cured triple extruded HVDC polymer

Insulation screen: Conductive PE

Bedding: Conductive swelling tapes

Metallic screen: Copper wires

Bedding: Conductive swelling tapes

Radial moisture barrier: Aluminum-PE laminate

Outer jacket: Polyethylene

© ABB Group October 26, 2011 | Slide 8

HVDC Light � 320 kV termination

Corona shield

Field grading adapters

Stress relief cone

Flange/box body

Insulator

Connector

Oil


HVDC Light JDC joint

Conductive layer

Deflector

Field grading layer

Insulation

Typical Submarine Cable – Up to 640 kV (±320 kV) DC

Conductor material: Copper

Conductor screen material: Conductive PE

Insulation type/material: Dry cured triple extruded HVDC polymer

Insulation screen: Conductive PE

Longitudinal water seal: Swelling tapes

Metallic sheath material: Lead alloy

Inner sheath material: Conductive PE

Armor material: Galvanized steel wires

Outer serving material: Polypropylene yarn

Submarine Cable – ±150 kV HVDC Light Approx 400 MW

Submarine Cable – ±320 kV HVDC Light Approx 800 MW


Submarine Cable Splices

PRODUCING HVDC CABLES

Karlskrona, Sweden Huntersville, NC (2012)

� ABB High Voltage Cable cable production sites� Karlskrona, Sweden

� Extruded and paper insulated cables for AC and DC� Underground and submarine cables

� Huntersville, North Carolina (In operation second half of 2012)� Extruded cables for AC and DC

� Underground cables

ABB High Voltage Cables - Manufacturing

� Huntersville, NC Cable Factory� Production Start in 2012� Technology transfer from the

Karlskrona plant� Conductor stranding� Extrusion line� Screening line� Sheathing line� Routine testing� Personnel� Know-how

ABB High Voltage Cables – New Land Cable Factory

Conductor stranding and lay-up

Vertical extruder

Material handling at our Supplier’s premises

� Quality standard is stated in specifications between ABB and theSupplier.

� The products are physically separated in batches and unique numbers are allocated for each batch for traceability.

� A certificate of analysis is issued for each batch and sent to ABB well before arrival of the shipment.

� The supplier has a completely closed material handling system, including the pellet sampling procedure.

� Example, Cleanroom filling of Octabins

© ABB Inc. October 26, 2011 | Slide 19

Material handling at the ABB cable factory

� The material handling system is completely closed throughout the production of the cable core.

� The octabin is cleaned upon arrival at ground level and then moved to a clean zone where a new outer cover of polyethylene is added� The octabin is cleaned again before being transported into a clean zone elevator to the material handling level in the extrusion tower � The octabin is connected to the material handling system via a closed glove box system

� Clean filtered air under over-pressure ensures that no contaminants are entering the inside of the octabin.

© ABB Inc. October 26, 2011 | Slide 20

Assembling

Lead and PE extrusion

Armouring

Turntable – storage of cable before loading

High voltage laboratory

InstallationUnderground Cables

Transport InstallOffload

Loading directly from the factory

INSTALLING HVDC CABLES

The Route Survey

� On-shore and off-shore route survey to be completed before issuing an RFP

� Route surveu to include

� Geographical conditions on the installation site including temperatures, water currents, wave heights, historical weather data, etc.

� Multibeam bathymetric survey (+- 0.5 m)

� Side scan sonar (50% overlapping, dual channels 100-500 kHz)

� Sub-bottom profiling (top 5 m surface sediments)

� Seabed sampling

� Shear strength

� Thermal resistivity

� Mark and record obstacles and other utility crossings

Cable Ampacity Rating

� Considerations:

� Load profile (load factor)

� Maximum conductor temperature

� 70°C for HVDC Light Cable

� Conductor size

� Thermal resistivity of ambient soil and backfill

� Temperature of ambient soil and air

� Laying depth

� Spacing between cables


Thermal Resistively Ambient Temperature


Burial Depth

Installation of Solid Dielectric CablesDuct bank system:Advantages – solid mechanical protection against dig-ins and external damage to the cables. (Important characteristic in roads and in areas with other utilities close by.)

Disadvantages – costly civil construction, more difficult cable pulling, higherthermo-mechanical stresses on joints, etc.

Installation of Solid Dielectric CablesDirect burial:Advantages – less costly civil construction, easier cable installation, less thermo-mechanical stresses on joints, etc.

Disadvantages – arguably less mechanical protection against dig-ins and external damage to the cables.

Cable Laying In Trench (Direct Burial)

Cable Installation in Duct-Banks

Jointing of XLPE Cable

The AMC Connector Cable Laying Vessel

�Developed by ABB and Aker Marine

�Dedicated Cable Laying Vessel

�Deep Sea

�Long Cable Length

�Heavy Loading (9000 ton)

�ROV’s and trenching machine operations

Horizontal Directional Drilling HDPE Pull Back

Solid Dielectric Cables for High Voltage Transmission Systems


Installation of submarine cables



� VIV suppressors to mitigate Vortex Induced Vibrations on free hanging cable in waters with high currents



�Off-shore education�Off-shore training�Health and safety�Correct equipment

RELIABILITY

Solid Dielectric Cables – Milestone Events

� In 1973 ABB began deliveries of solid dielectric (“XLPE”) cable systems for voltage ratings up to 145 kV.

� In 1984 ABB furnished and commissioned a complete XLPE transmission cable system rated 220 kV for a municipal power company in Stockholm.

� In the mid 1980s ABB introduced transmission cable terminations with pre-molded stress-cones.

� In 1990 ABB introduced pre-molded joints for XLPE transmission cables.� In 1997 ABB introduced solid dielectric cable systems for direct current

transmission (“HVDC Light”).� In 1998 ABB furnished and commissioned a complete XLPE cable

system rated 420 kV for BEWAG in Berlin. � In 2002 ABB commissioned the longest underground transmission circuit

in the world (Murray link in Australia – two parallel 110-mile long solid dielectric HVDC Light cables rated 200 MW and ±150 kV);

� In 2002 ABB commissioned a 24-mile long solid dielectric submarine cable circuit (HVDC Light) across the Long Island Sound rated 330 MW, ±150 kV;

Reliability of Solid Dielectric Cable Systems

� During the last 30+ years, the quality for XLPE materials and manufacturing processes has continually improved.

� The development of XLPE cables for EHV applications would not have been possible without these continued improvements.

� While the electrical stress level on the XLPE Insulation has continuously increased over time, the failure rate and unavailability of XLPE cable systems has dramatically decreased .

� Application of Super Clean XLPE Insulation System using VerticalContinuous Vulcanization (VCV) Line:

� Advanced control system� Check for quality

� Check for cleanliness

� Check for centricity

Reliability of Solid Dielectric Cable Systems

� HVDC Light

� No internal cable fault in 1566 km HVDC Light cables put into operation

� HVAC for comparison

HVDC - HISTORY AND REFERENCE PROJECTS

ABB HVDC Classic Projects around the World

Classic HVDC Submarine Cable

Mass Impregnated Non Draining (“MIND”) paper insulation

Significant technology milestone events� 1953 – Gotland I: ±100 kV, 20 MW, 62 miles� 1968 – KontiSkan I: ±285 kV, 300 MW, 40 miles� 1989 – FennoSkan: ±400 kV, 500 MW, 124 miles� 1994 – Baltic Cable: ±450 kV, 600 MW, 155 miles� 1996 – Single-Circuit ratings up to ±500 kV, 800 MW� 1999 – SwePol Cable: ±450 kV, 600 MW, 143 miles� 2007 – NorNed Cable: ±450 kV, 700 MW, 360 miles� 2009 – BritNed Cable: ±450 kV, 1000 MW, 300 miles

Mass impregnated cable is not practical for long distance underground installations.


1999Gotland160 kV (±80 kV)50 MW43 miles

2000Direct Link160 kV (±80 kV) 3×60 MW3×40 miles

2002Murray link300 kV (±150 kV), 220 MW112 miles

2006EstLink300 kV (±150 kV), 350 MW20 miles (+46 miles subsea)

2008BorWin (Nord E.On 1)300 kV (±150 kV), 400 MW47 miles (+80 miles subsea)

2009Eirgrid400 kV (±200 kV), 500 MW44 miles (+116 miles subsea)

20072500 mm2 Cu or Al640 kV (±320 kV), up to 1100 MW

2010DolWin640 kV (±320 kV), 800 MW56 miles (+46 miles subsea)

ABB’s HVDC cable technology advancements now make long EHV underground transmission circuits feasible

Solid Dielectric HVDC Light® Submarine CableSignificant technology milestone events� 2002 – Cross Sound: 300kV(±150kV), 330MW, 25 miles� 2005 – Troll A: 120kV (±60kV), 2×40MW, 2×42 miles� 2006 – EstLink: 300kV (±150kV), 350MW, 46 miles� 2007 – Circuit ratings up to 640kV (±320kV), 1100MW� 2008 – BorWin: 300kV (±150kV), 400MW, 80 miles� 2009 – Eirgrid: 400kV (±200kV), 500MW, 116 miles� 2010 – DolWin: 640kV (±320kV), 800MW, 46 miles


100 kV MI cable systemGotland - Swedish mainland

Project

100 kV DC cable system for State Power Board, Sweden

Cabletype

Mass-impregnated1 x 90 mm2 Cu

Length 100 km

Year 1953


450 kV MI Cable System, NorNed

Project

450 kV DC 700 MW Cable System Norway – TheNetherlands forStatnett / TenneT

ABBCables 270 km MI 2 x 790 mm2

Cu DWA

2 x 150 km MI 700 mm2 CuDWA

ABBScopeof supply

HVDC CablesInstallation servicesConvertor Stations

Constru-ction 2005 - 2008


450 kV MI cable system, BritNed

Project

450 kV DC, 1000 MW cable system for the BritNed connection between Great Britain and the Netherlands for BritNed Ltd

Cabletype MI 1 x 1430 mm2 Cu

Length 494 km submarine cable 16 km land cable

Scopeofsupply

Cable system, including accessories and installation

Year 2009 - 2010


+/-150 kV HVDC Light cable system, Cross Sound

New Haven

Long Island SoundNew York

Shoreham

Project +/-150 kV HVDC Light cable systemTransEnergieUS

Cable type HVDC Light 1 x 1300 mm2 Culead sheath

Length 2 x 42 km = 84 km

Scope ofsupply

Project management, cable system, converters, installation, trial operation

Year 2002


80 kV HVDC Light cable system, Troll A North Sea

Project

80 kV HVDC Light submarine cable system for feeding gas compressors at Statoil’s Troll A gas production platform

Cabletype

HVDC Light 1 x 300 mm2 Cu, double armoured submarine cable

Length 4 x 68 km

Scopeofsupply

Cable system design, project management, cable and accessories, land- and offshore installation and testing

Year 2002 - 2004


150 kV HVDC Light cable system, Estlink

Project

150 kV HVDC Light submarine cable, 350 MW AS Nordic Energy Link

Cabletype

HVDC Light 1 x 1000 mm2 Cu armoured submarine cable HVDC Light 1 x 2000 mm2 Al land cable

Length 2 x 75 km submarine cable 2 x 29 km land

ABBScopeofsupply

Cable system design, project management, cable and accessories, land- and offshore installation, testing

Year 2006


+/-150 kV HVDC Light cable system, NORD E.ON 1

The world’s largest offshore wind farm

Project +/-150 kV HVDC Light cable system E.on Netz, Germany

Cable typeHVDC Light 1 x 1200 mm2 Cu and 1 x 1600 mm2 Cu (sea) HVDC Light 1 x 2300 mm2 Al (land) XLPE 3 x 800 mm2 Cu (170 kV sea)

Length117 km x 2 submarine DC cable route75 km x 2 underground DC cable route1 km submarine AC cable route

Scope of supply Project management, cable system, converters, civil works, installation, trial operation

Year 2009


200 kV HVDC Light cable system, EWIP

Project 200 kV DC cable system for Eirgrid, Ireland

Cabletype

HVDC Light 1x2210 mm2 AlHVDC Light 1x1650 mm2 CuXLPE 1 x 1600 mm2 Al

Length

186 km submarine DC cable76 km underground DC cable3 km underground 400 kV AC cable

Scopeofsupply

Cable system design, cable with integrated fiber optic cable and DTS system, cable accessories, installation and testing.

Year 2012


+/-320 kV HVDC Light cable system, DolWin1

ABB’s largest power transmission order

ever

Project +/-320 kV HVDC Light cable system, transpower, Germany

Cable typeHVDC Light 1 x 1000 mm2 Cu and 1 x 1600 mm2 Cu (sea) HVDC Light 1 x 2000 mm2 Al, 1 x 1600 mm2 Cu (land) XLPE 3 x 800 mm2 Cu (sea) with integrated fiber optics

Length74 km x 2 submarine DC cable route90 km x 2 underground DC cable route7,5 km submarine AC cable route

Scope of supply Project management, cable system, converters, civil works, installation, trial operation

Year 2012-2013

+/-300 kV HVDC Light cable system, Nordbalt

+/-320 kV HVDC Light cable system, DolWin2 (900 MW)

3. HVDC Cables 2

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