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

HVDC Cable Systems

Underground and Subsea

ABB Group Slide 1 PowDoc id

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 Systems

Characteristics:

Absence of insulating fluids eliminates the risk of

accidental release of hazardous materials and substances into the environment;

Lower maintenance costs (solid dielectric cables

are 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 permits temporary suspension of splicing during morning and afternoon rush hour traffic).

Cables are suitable for direct burial in open

trenches at a lower overall installation cost than using 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: polymer Insulation screen: Bedding: Metallic screen: Bedding: Radial moisture barrier: Outer jacket: Dry cured triple extruded HVDC

Conductive PE Conductive swelling tapes Copper wires Conductive swelling tapes Aluminum-PE laminate Polyethylene

HVDC Light 320 kV termination

Corona shield Connector

Field grading adapters Oil Stress relief cone Flange/box body

Insulator

ABB Group October 26, 2011 | Slide 8

HVDC Light JDC joint

Insulation

Conductive layer Deflector Field grading layer

ABB Group October 26, 2011 | Slide 9

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

Conductor material:

Copper

Conductor screen material: Conductive PE Insulation type/material: polymer Insulation screen: Longitudinal water seal: Metallic sheath material: Inner sheath material: Armor material: Outer serving material: Dry cured triple extruded HVDC

Conductive PE Swelling tapes Lead alloy Conductive PE Galvanized steel wires Polypropylene yarn

Submarine Cable 150 kV HVDC Light Approx 400 MW

Submarine Cable 320 kV HVDC Light Approx 800 MW

Submarine Cable Splices

ABB Group October 26, 2011 | Slide 13

PRODUCING HVDC CABLES

ABB High Voltage Cables - Manufacturing

Karlskrona, Sweden

Huntersville, NC (2012)
Karlskrona, Sweden

ABB High Voltage Cable cable production sites

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 New Land Cable Factory

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

Conductor stranding and lay-up

Vertical extruder

Material handling at our Suppliers premises

Quality standard is stated in specifications between ABB and the

Supplier.

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

Installation Underground Cables

Transport

Offload

Install

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 70C for HVDC Light Cable Conductor size Thermal resistivity of ambient soil and backfill Temperature of ambient soil and air Laying depth Spacing between cables

Cable Ampacity Rating

Thermal Resistively Ambient Temperature

Cable Ampacity Rating

Burial Depth

Installation of Solid Dielectric Cables

Duct 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, higher thermo-mechanical stresses on joints, etc.

Installation of Solid Dielectric Cables

Direct burial:
Advantages less costly civil construction, easier cable installation, less thermomechanical 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 Dedicated Deep Long

by ABB and Aker Marine

Cable Laying Vessel

Sea Cable Length Loading (9000 ton)

Heavy ROVs

and trenching machine operations

Solid Dielectric Cables for High Voltage Transmission Systems

Horizontal Directional Drilling HDPE Pull Back

Solid Dielectric Cables for High Voltage Transmission Systems

Installation of submarine cables

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

Solid Dielectric Cables for High Voltage Transmission Systems

Installation of submarine cables 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. pre-molded stress-cones.

In the mid 1980s ABB introduced transmission cable terminations with 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 Vertical Continuous 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.

Solid Dielectric Cables for High Voltage Transmission Systems

ABBs HVDC cable technology advancements now make long EHV underground transmission circuits feasible
1999 Gotland 160 kV (80 kV) 50 MW 43 miles 2000 Direct Link 160 kV (80 kV) 360 MW 340 miles 2002 Murray link 300 kV (150 kV), 220 MW 112 miles 2006 EstLink 300 kV (150 kV), 350 MW 20 miles (+46 miles subsea) 2008 BorWin (Nord E.On 1) 300 kV (150 kV), 400 MW 47 miles (+80 miles subsea) 2009 Eirgrid 400 kV (200 kV), 500 MW 44 miles (+116 miles subsea) 2007 2500 mm2 Cu or Al 640 kV (320 kV), up to 1100 MW 2010 DolWin 640 kV (320 kV), 800 MW 56 miles (+46 miles subsea)

Solid Dielectric HVDC Light Submarine Cable

Significant technology milestone events 2002 Cross Sound: 300kV(150kV), 330MW, 25 miles 2005 Troll A: 120kV (60kV), 240MW, 242 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 system Gotland - Swedish mainland

100 kV DC cable system for State Project Power Board, Sweden Cable type Mass-impregnated 1 x 90 mm2 Cu

Length 100 km Year 1953

ABB Group October 26, 2011 | Slide 52

450 kV MI Cable System, NorNed

Project

450 kV DC 700 MW Cable System Norway The Netherlands for Statnett / TenneT 270 km 2 x 150 km MI 2 x 790 mm2 Cu DWA MI 700 mm2 Cu DWA

ABB Cables

HVDC Cables ABB Installation services Scope of supply Convertor Stations Constru2005 - 2008 ction
ABB Group October 26, 2011 | Slide 53

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 MI 1 x 1430 mm2 Cu 494 km submarine cable 16 km land cable Cable system, including accessories and installation

Cable type Length Scope of supply

Year

2009 - 2010

ABB Group October 26, 2011 | Slide 54

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

New Haven Long Island Sound New York Shoreham

Project Cable type Length Scope of supply Year

ABB Group October 26, 2011 | Slide 55

+/-150 kV HVDC Light cable system TransEnergieUS HVDC Light 1 x 1300 mm2 Cu lead sheath 2 x 42 km = 84 km Project management, cable system, converters, installation, trial operation 2002

80 kV HVDC Light cable system, Troll A North Sea

Project

Cable type Length Scope of supply Year

ABB Group October 26, 2011 | Slide 56

80 kV HVDC Light submarine cable system for feeding gas compressors at Statoils Troll A gas production platform HVDC Light 1 x 300 mm2 Cu, double armoured submarine cable 4 x 68 km Cable system design, project management, cable and accessories, land- and offshore installation and testing 2002 - 2004

150 kV HVDC Light cable system, Estlink

Project

150 kV HVDC Light submarine cable, 350 MW AS Nordic Energy Link HVDC Light 1 x 1000 mm2 Cu armoured submarine cable HVDC Light 1 x 2000 mm2 Al land cable 2 x 75 km submarine cable 2 x 29 km land Cable system design, project management, cable and accessories, land- and offshore installation, testing 2006

Cable type

Length ABB Scope of supply Year

ABB Group October 26, 2011 | Slide 57

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

The worlds largest offshore wind farm

Project Cable type

+/-150 kV HVDC Light cable system E.on Netz, Germany HVDC 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) 117 km x 2 submarine DC cable route 75 km x 2 underground DC cable route 1 km submarine AC cable route Project management, cable system, converters, civil works, installation, trial operation 2009

Length

Scope of supply Year

ABB Group October 26, 2011 | Slide 58

200 kV HVDC Light cable system, EWIP

Project

200 kV DC cable system for Eirgrid, Ireland HVDC Light 1x2210 mm2 Al HVDC Light 1x1650 mm2 Cu XLPE 1 x 1600 mm2 Al 186 km submarine DC cable 76 km underground DC cable 3 km underground 400 kV AC cable Cable system design, cable with integrated fiber optic cable and DTS system, cable accessories, installation and testing. 2012

Cable type

Length

Scope of supply Year

ABB Group October 26, 2011 | Slide 59

+/-320 kV HVDC Light cable system, DolWin1

ABBs largest power transmission order ever

Project Cable type

+/-320 kV HVDC Light cable system, transpower, Germany HVDC 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 74 km x 2 submarine DC cable route 90 km x 2 underground DC cable route 7,5 km submarine AC cable route Project management, cable system, converters, civil works, installation, trial operation 2012-2013

Length

Scope of supply Year

ABB Group October 26, 2011 | Slide 60

+/-300 kV HVDC Light cable system, Nordbalt

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