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Powerline Conductor Accelerated Testing (PCAT)
Prinicipal Investigator: Philip Irminger Oak Ridge National Laboratory
[email protected] Team: Dan King, Michael Starke, Marcus Young, Zhi Li,
Ben Ollis, Mark Buckner, Joe Gracia June 10-11, 2015 Washington, DC
DOE/OE Transmission Reliability Program
Topics to Address
Recap on what is PCAT and why is it here?
Previous Capabilities & Challenges
Status of Current Upgrades & Test Results
2
Recap - History: Powerline Conductor Accelerated Testing Facility – Why is it here?
3
“DOE will develop national transmission-technology testing
facilities that encourage partnering with industry to
demonstrate advanced technologies in controlled
environments.
Working with TVA, DOE will create an industry cost-shared
transmission line testing center at DOE ’s Oak Ridge National
Laboratory (with at least a 50 percent industry cost share).”
2002 - National Transmission Grid Study
- One of the 51 Recommendations -
Originally built for the 3M Composite Conductor
development, now available for any manufacturer to
validate their product.
Recap: Past Accomplishments PCAT has been in operation for
over 10 years
The PCAT facility has been used to test many different conductors and sensors:
– 3M 477 kcmil ACCR
– 3M 675 kcmil ACCR
– Southwire 1113 kcmil ACSR FO
– Power Donut2
– 3M 1272 kcmil ACCR
– 3M 795 kcmil ACCR
– Southwire C7 Overhead Conductor
– Others
4
Recap - Capabilities: Powerline Conductor Accelerated Testing Facility
5
Testing Capabilities
– Thermal / Mechanical Cycling
– Current / Temperature Ramp
– Current / Temperature Steps and Hold
– Controlled current testing
– Controlled temperature testing
Facility
– 2400 feet of conductor
– two 600 foot spans
– 3 towers
– 0 to 400 Vdc
– 0 to 5,000 Adc
– Conductor and accessories
– Tested up to 300oC
– can go higher if needed
6
Recap: Driver of higher operating temperatures is higher current ratings
Need to test / verify new conductors over entire operating range
0
50
100
150
200
250
0 500 1000 1500 2000
Ampacity, amps
Op
era
tin
g T
em
pera
ture
, °C
Conventional Conductors
ACSR, ACAR, and AAC
High Temperature Conductors
Over temperature causes annealing
and loss of strength for
Conventional Conductors
Recap: Benefit of a high temp/low sag conductor
7
NESC Required Minimum Clearance
Conv. Conductor
High Temp/Low Sag Conductor No Load Condition
Ground
More ampacity while still meeting the National
Electric Safety Code (NESC) required minimum
clearance
Recap: Existing Infrastructure 8
PCAT Control House
DC Supply
9
Recap: Conductors are installed by TVA using conventional industry practices
Typical installation is ~ 3-4 days
Where PCAT fits?
PCAT provides a unique transmission conductor testing facility to augment utility field tests and demonstrations
Each conductor test undertaken in collaboration with industrial partner
10
How is PCAT Unique?
Who else does this in the US?
Other Facilities:
– KEMA – No Overhead testing in US
– NEETRAC – Primarily indoor
– EPRI – Charlotte is indoor, Lennox could add outdoor testing, but currently not present
Only facility in North America where there are realistic spans, realistic environment, and realistic loads
11
Historical Data Collection – Visual Basic 12
Temperature
(Thermocouples)
Sag
(Laser Based)
Weather
(Weather Station)
Tension, Net Radiation
(CAT-1)
DC Supply Control
(V and I Setpoints,
Startup/shutdown)
Temperature, status,
voltage current
measurements.
RS485
RS485
RS232
Fiber Optic
RS485
RS485
DC Power Supply
Fiber Optic
ComputerRS485/FO
RS485/FO
RS232/FO
RS485/FO
RS485/FO
Fiber Optic
Conductor/accessory temperature
– Surface contact or conductor core
– Upto 128 thermocouples
Applied current and voltage
– Measured by power supply
Conductor sag
– Laser at mid-span
Conductor tension
– Load cells on both circuits
Weather
– Ambient temperature, wind speed, wind direction
– Conductor net radiation sensor
PC-based data acquisition system
– 10 second polling, 1 minute data archive
*Note: combined at midnight, non real-time
Historical Challenges to Testing 13
Lightning strikes have damaged many sensors
System lacked flexibility to adapt test plans and analysis to meet specific vendor needs: Legacy software was in Visual Basic, original programmer has since retired.
Measurement resolution Inability to investigate short duration phenomena
Inability to detect bad data Unable to validate measurements using multiple sources (diverse
measurement technologies)
Conductor Right-of-Way Encroachment Tree limbs were in close proximity to conductor including touching at times
Current Activities 14
Rehabilitating PCAT Data Acquisition, Controls, and Visualization:
Replaced broken, obsolete and inflexible parts
Transitioning control from Visual Basic to LabVIEW.
Integrate new sensors including thermal imaging of conductor
Integrate continuous CAT-1 data feed
Implement real-time remote monitoring and warning system
Continue testing
Installed and currently testing General Cable ACSS Drake 795 Conductor One side coated, One side non-coated
Cable and Accessory
Temperatures
(thermocouple modules)
Sag Measurement
(laser based)
Weather Station
Tension measurement
(CAT-1), other
Voltage and Current
Setpoints, Startup/
shutdown
Temperature, status,
voltage current
measurements.
Thermal imaging camera
Sag Measurement
(camera, DGPS, freq)
RS485
RS485
RS232
Fiber Optic
RS485
RS485
Power Supply Trailer
Fiber Optic
Labview PXI Chassis
Fiber Optic
RS485/FO
RS485/FO
RS485/FO
RS485/FO
RS232/FO
General Cable Test Results
0
20
40
60
80
100
120
0:0
02
:24
4:4
87
:13
9:3
81
2:0
21
4:2
61
6:5
01
9:1
52
1:4
00
:05
2:2
94
:54
7:1
99
:43
12
:07
14
:31
16
:55
19
:20
21
:44
0:0
82
:32
4:5
67
:20
9:4
51
2:1
01
4:3
41
6:5
81
9:2
42
1:4
80
:13
2:3
75
:01
7:2
59
:50
12
:14
14
:38
17
:02
19
:26
21
:50
0:1
62
:40
5:0
47
:28
9:5
31
2:1
71
4:4
11
7:0
61
9:3
02
1:5
4
Day End
Coated
Uncoated
1 2 3 4 5
Day
Con
du
cto
r T
emp
eratu
re (
oC
)
5 days of testing at
different current levels
General Cable Test Results
0
5
10
15
20
25
30
35
40
45
50
0:0
02
:27
4:5
47
:22
9:5
01
2:1
71
4:4
41
7:1
21
9:4
02
2:0
80
:35
3:0
35
:30
7:5
81
0:2
51
2:5
21
5:1
91
7:4
62
0:1
42
2:4
11
:08
3:3
56
:02
8:2
91
0:5
71
3:2
51
5:5
21
8:2
02
0:4
82
3:1
51
:43
4:1
06
:37
9:0
51
1:3
21
3:5
91
6:2
61
8:5
32
1:2
02
3:4
92
:16
4:4
37
:10
9:3
71
2:0
51
4:3
21
7:0
01
9:2
72
1:5
4
Day End
1 2 3 4 5
Day
% R
edu
ctio
n i
n T
emp
eratu
re f
or
E3X
Con
du
cto
r
% Reduction between
coated and non-coated
General Cable Test Results C
on
du
cto
r T
emp
eratu
re (
oC
)
Temperature profile at
1425A
General Cable Test Results 18
Ambient
Temp (°C)
Wind Velocity
(ft/s)
Uncoated
Conductor
(°C)
Coated
Conductor
(°C)
%
Reduction
Differential
Sag (ft.)
9 1.1 - 3.6 90 72 20% 0.5
8 0 - 4.7 119 90 24% 0.7
8 4.4 - 5.7 125 94 25% 0.9
6 0.2 - 3.2 166 125 25% 1.5
6 0.4 – 4.8 200 150 25% 1.6
4 NA 240 174 28% 2.25
2 2.1 - 2.2 275 190 31% 2.85
Conductor: ACSS Drake 795kcmil
20-30% Reductions in Operating Temperature and Sag for
Coated Conductor vs Uncoated Conductor
Right of Way Clearing
Current Right of Way was encroaching on the conductor
At times would have tree contact with conductor
Cleared a large Right of Way (~15’) for the Conductor to ensure uninterrupted testing
19
Thermocouple Upgrade
Thermocouple modules all updated to I-7018-R modules
Every channel individually checked to ensure valid identification and labeling
Added open circuit thermocouple detection to the module enabling identification of unused thermocouples
20
PCAT LabVIEW implementation using Actor Framework
21
Messages Actors
Config
Files
Advantages
• Measurements, processing, and controls
performed asynchronously and in
parallel
• Allows adding new measurement or
control capabilities without affecting
current functionality
• Enables rapid development of additional
measurements and new controls
Initial Thermal Investigation
Roadside tracker with 2 FLIR Tau 2 Longwave Infrared (LWIR) cameras (640 by 512).
9 mm lens with focal length providing a 70 degree horizontal view angle.
22
Selected Thermal Camera
Purchased A310f 15°FLIR Camera
Currently integrating with LabVIEW front panel, followed by embedded image processing for sag and temperature analysis
23
Planned Installation Site,
2nd at other end once
validated
Additional sensors
Material Transfer Agreement has been executed with UC Synergetics to implement their ThermalRate System
– Plans to expand into a CRADA
Plans to install the system during June and incorporate into the LabVIEW data feed
Will provide feedback on any beneficial features
24
Risk Factors 25
Glitches during cutover to new control system.
– Have minimized risk by paralleling the serial connection to keep it connected to both sets of controllers.
Unfavorable weather conditions
– Because sustained bad weather is not predicted, this is only a minor risk to the schedule.
Proposed FY16 Activities 26
Continue conductor testing
Finish integrating additional sensors
Enhance Real-time controls
Expand PCAT test capability to include alternating current
– Add a DC to AC inverter stage to the current infrastructure
– Conduct additional testing including: • Perform conductor testing of steady state and transient conditions at grid frequency
accounting for all the effects of the AC EM field
• Test and experiment with measurement devices and auxiliary equipment including: – Dynamic Line Rating Devices
– PMUs
– CTs
– VTs
– Other devices intended for ac powerline applications
• Test and experiment with different power flow control devices – Smart Wire
– Power Donut
– ORNL’s Continuously Variable Series Reactor (CVSR)
– Others
• Investigate the impact of AC EM field on different devices/objects along the right-of-way
Q&A 27