The AmpaCity Project

T&D World Magazine

By Frank Merschel, RWE Deutschland AG, and Mathias Noe, Karlsruhe Institute of Technology
Mon, 2013-12-23 18:42

The existing distribution network in Essen, a major city in the German Rhein-Ruhr
Rhein
area, was
constructed when a central power supply together with large industry dominated the townscape and
infrastructure. Essens distribution network then consisted of several 110-kV
kV underground cables
supplying 10-kV
kV distribution substations. However, because of economic and structural changes in
the Ruhr area, coupled with the expiring service life of some of the existing assets, larger investments
will bee needed for the refurbishment and modernization of this distribution network in the coming
years.
Faced with these investment decisions, the local distribution network operator, RWE Deutschland
AG, sought to explore all of the potential options to identif
identify
y the best possible solution for the
medium- and long-term
term distribution network refurbishment and reinforcement. As a first step,
RWE, the Karlsruhe Institute of Technology (KIT), the University of Hannover and cable
manufacturer Nexans conducted a study tto
o investigate the technical feasibility and requirements for
an economically justified application of integrating a high
high-temperature
temperature superconductor (HTS)
system into the distribution network.
HTS cable systems have the potential to revolutionize the design and load-transfer
transfer capacity of the
distribution network because they carry five times the current of a conventional cable system with
the same outer dimensions. For this reason, an HTS cable system was selected for use within the
AmpaCity project in the city
ty center of Essen. The HTS system replaced a conventional high-voltage
high
cable system by connecting the medium
medium-voltage
voltage busbars of two substations. AmpaCity serves as a
lighthouse project because it is the first time a 11-km (0.62-mile)
mile) HTS cable system was installed
i
with
an HTS fault current limiter in a distribution network within a city center. Additionally, it is the
longest installed HTS cable system in the world.

High-Temperature Superconductors
Superconductors are materials that lose their electrical resistance when cooled to below their socalled critical temperature (Tc). The state of superconductivity also requires being below a certain
magnetic field magnitude, and the transport current in the material must not exceed a critical
current density. Superconductors have been well known for more than 100 years, but it was in 1986
the present class of high-temperature superconductors was discovered. In contrast to previously
known superconducting metals and alloys, the HTS materials of today are ceramic substances.
Because of the higher critical temperature for these materials, the effort needed for cooling is
strongly reduced. In 1987, the first superconductor, yttrium barium copper oxide (YBCO; Tc = -181C
[-294F]), with a critical temperature above -196C (-321F) was discovered. This was considered a
breakthrough as that level of cooling could be readily provided by available liquid nitrogen
technology. Since then, scientists and engineers have worked on developing flexible conductors made
from these novel materials that are suitable for energy technology applications.

Today, superconductor cables can carry a multiple of the current that a conventional cable of the
same cross-section can carry, even allowing for the cryogenic envelope (thermal insulation) of the
HTS cable. Therefore, the application of HTS cables can provide an economical alternative for large
power connections provided the following are met:

Relatively high currents have to be transported over relatively short distances.

Medium-voltage HTS cables are employed instead of conventional high-voltage cables; as a
result, a simpler network structure and other secondary benefits are achieved.
The cost of HTS wires and cooling systems decreases.

Forecast of Future HTS Costs

As a result of the rapid advancements in HTS material development, the cost of HTS wires is
expected to drop considerably within the next 10 years. This will result from the scaling effects
because of higher demand and production rates, and the increasing current-carrying capacity of the
HTS material. The higher the superconductors current density, the less superconducting wire is
needed to build electrical power devices, an effect that also will contribute to the decrease in cost.
Despite the higher investment costs for superconductor cable systems, the implementation can be
recommended because HTS cables have several advantages over conventional cables:

Owing to the quasi zero resistance, large currents can be transported at the medium-voltage
level so intracity high-voltage equipment as well as high-voltage transformers become
dispensable.
The reduction in the number of high- and medium-voltage transformers required effectively
reduces land requirements in high-value city center regions.
The omission of conventional cable systems and switchgear reduces the distribution network
losses.
The HTS medium-voltage concentric cable systems reduce the width of the right-of-way and
cable installation costs significantly.
A characteristic of their design is that HTS cables do not produce external electromagnetic
fields.
HTS cables do not emit heat; hence, there is no drying out of soil and no reduction in the
transmission capacity when crossing other cables and vice versa.

Economic Comparisons
The economic comparison of different network configurations was based on a 110-kV network design
to supply the forecasted maximum demand for Essens city center in 2020. RWE compared the
existing 110-kV network design concept with an innovative grid concept based on a 10-kV
infrastructure, which exhibits the same redundancy and is rated for the same load requirements. The
network design concept with 10-kV infrastructure would require fewer 110-kV cable circuits and
substations. This network could be reinforced with superconducting as well as conventional 10-kV
cable systems.
If RWE were to change the system design concept from a 110-kV to a 10-kV network, four 110-kV
substations, five 110/10-kV transformers with associated switchgear and 12 km (7.5 miles) of 110-kV
cable system would become obsolete. In contrast, for the 10-kV network design concept, three 10-kV
bus ties and 23.4 km (14.5 miles) of 10-kV cable circuits with the associated 10-kV switchgear for
eight connections would be required.

Future HTS Systems

The feasibility studies, including the cost of conventional cable and HTS cable, were evaluated based
on the expected future cost structure. Three different network options were compared, taking into
account only those sections of the network requiring change. The first option was a 110-kV network
employing conventional cable systems, the second option was a 10-kV network with conventional
cable systems, and the third option was a 10-kV network with HTS cable systems. The assumptions
used in the economic comparison were a lifetime of 40 years, an interest rate of 6.5% for determining
the net present value and a 2% per annum increase in operating costs.
The overall results showed the net present value of the option with superconducting cables was
below the option employing conventional 110-kV cable systems. The design option based on
conventional 10-kV cable systems proved to be the most economical. However, after due
consideration of the cost of electrical losses, which would be higher with this option than the HTS
cable option, and the large space requirement for the installation that would prohibit its use in
densely populated areas, the HTS cable option was deemed the preferred option based on life-cycle
costs.
The installation of superconducting cable systems might be the best option based on technical and
economic considerations. In large cities, like Essen, one of the most important aspects is the space
requirements for the installation. The transmission of 40 MVA between two substations can be
realized with one conventional high-voltage cable system (three single-phase cables), a
superconducting cable system (one three-phase cable) or five conventional medium-voltage cable
systems (15 single-phase cables). Each of these options has different cable installation and space
requirements

HTS Cable System Implementation

The space beneath the streets of many city centers is quite restricted by the multiplicity of utility
services, therefore, more attention has to be given to the space required for cable installations. This
was a primary reason RWE decided to install a superconducting cable system in Essens city center.
Installation took place in October 2013. The 1-km-long 10-kV HTS system in the city center
interconnects two existing substations. Because of the innovative nature of the AmpaCity project, it
is funded by the Energy Research unit of the German Federal Ministry of Economics and Technology
(BMWi). The total project cost 13.5 million euros (US$17.5 million), including funding of
approximately 6 million euros ($7.79 million).

Main System Components

The 10-kV HTS system, manufactured by Nexans with a transmission capacity of 40 MVA, comprises
a three-phase superconducting cable with concentrically arranged phase conductors and a
superconducting fault current limiter. For the cable, KIT characterized suitable HTS materials,
performed simulation studies and supported the project scientifically. Further components of the
HTS system are as follows:

Two terminations in which the transition between superconductor and conventional

conductor materials as well as the thermal transition are realized
One joint installed approximately in the middle of the route to connect two cable sections
A cooling system that supplies liquid nitrogen for the cooling of the cable and fault current
limiter.

As a result of reducing space requirements, the concentric arrangement of the three-phase

conductors in the superconducting cable eliminates electromagnetic field emissions during normal
operation. The outer diameter of the cable including the cryostat (thermal insulation) and a
polyethylene sheath is approximately 150 mm (6 inches).
The terminations serve as the transition connection between the superconducting cable and the
conventional cable, also providing the cooling system connection. Liquid nitrogen is used to cool the
cable to the operating temperature. Therefore, in the terminations, a compensation of approximately
200K (-99F) temperature difference is achieved, and it is this thermal transition that determines
the size of the termination.

Lab Tests
While the superconducting fault current limiter is manufactured based on a proven design, all
components of the AmpaCity cable system cables, joints and terminations were new
developments and, therefore, needed required testing in the laboratory. The first pre-prototype tests
were completed successfully in November 2012.
The main test objectives were the verification of the cable design with respect to high-voltage and
mechanical requirements, as well as the verification of the termination design. For the high-voltage
tests, a 30-m (98-ft) length of the pre-prototype cable with two prototype terminations was set up in
a loop in Nexans Hannover laboratory. The design of the pre-prototype cable was the same as the
AmpaCity cable only, for cost reasons, most of the superconducting tapes were replaced by copper
tapes with the same dimensions. On the pre-prototype setup, high-voltage tests were carried out
including partial-discharge measurements, lightning impulse voltage tests as well as alternating
current voltage-withstand tests.
In addition, mechanical bending tests were performed with a 20-m (66-ft) section of the preprototype cable. After bending the cable multiple times, 2-m (7-ft) samples were cut. Each sample
was dissected and the critical current of the recovered superconducting tapes was measured. All the
superconducting tapes were measured and no degradation of critical current was observed.
The successfully completed tests on the pre-prototype cable were followed by a type test in spring
2013. The type test setup included two sections of an entirely superconducting prototype cable, one
joint and two terminations. Type tests were finished successfully in March 2013, and production of
the final 1-km-long cable started. The installation of this cable in the city center of Essen took place
in October 2013, including the assembly of terminations and joint. Nexans was responsible for
installing and commissioning the HTS system and fault current limiter. In the winter 2013-2014, the
cryogenic system serving the HTS system will have its behavior tested for the first time under load
conditions.

Flagship Project
The HTS network is subject to field testing for a period of at least two years. This testing regime
includes the fault current limiter, and cable and cooling system. The experience gained during this
field-test period will be of great importance, both for RWE in terms of future expansion and
refurbishing of urban power networks, as well as for the superconductor industry.
The success of this project can contribute significantly to the acceptance of the superconductor
technology by potential users, and through an increased demand, it also can lead to increased
production with associated cost reduction of superconducting tapes for power industry applications.

Acknowledgement
The authors wish to acknowledge the technical support and advice given by Mark Stemmle and
Achim Hobl, both experts in the field of superconductivity at Nexans.

Frank Merschel (frank.merschel@rwe.com), following his studies at the Leibniz Universitt

Hannover and graduation with a thesis on electrical insulation materials, worked in different
occupations and locations in the German utility RWE. Presently, he is coordinating research and
development projects in the distribution grids of the RWE group. In addition, Merschel is working in
the field of cable standardization and is a lecturer in cable technology for energy and communication
cables at the Leibniz Universitt Hannover.
Mathias Noe (Mathias.Noe@kit.edu) holds a masters degree in power engineering and a Ph.D. from
the Leibniz Universitt Hannover. After a postdoctoral position at the Ecole Polytechnic Federale de
Lausanne in Switzerland, he joined Forschungszentrum Karlsruhe in 1998 and became a group
leader for high-temperature superconducting power devices at the Institute for Technical Physics.
Noe is the director of the Institute for Technical Physics at the Forschungszentrum Karlsruhe and a
professor for technical applications of high-temperature superconductivity.