A Solid State Transformer for Electric Power Grid HEMP/GMD Protection
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Donnelly, Timothy James↗
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Solid State Transformer Architecture and Control Compensation for Common Mode Currents
A high-altitude electromagnetic pulse (HEMP) or similar geomagnetic disturbance (GMD) has the potential to impact the operation of large-scale electric power grids. By introducing low-frequency common-mode (CM) currents, these events can degrade the performance of critical system components, such as large power transformers by introducing CM currents which can lead to magnetic saturation of the transformer core. In this work, a solid-state transformer (SST) is developed to replace susceptible equipment and improve grid resiliency by safely absorbing these CM disturbances. This device will be referred to as a common-mode solid-state transformer (CM-SST). An SST architecture based on a four-legged AC/DC converter is developed. This architecture enables active control of CM signals without disturbing the AC voltages or the real and reactive power delivery capabilities. A system-level model of this architecture is created, and time-domain simulations are performed to evaluate the SST’s performance in response to simulated CM disturbances. A control strategy for mitigating CM current is also investigated. Hamiltonian surface shaping and power flow control (HSSPFC) is used to design a nonlinear controller for the SST’s output inverter. The objectives of the controller are to suppress CM-induced AC current offsets and regulate AC currents to desired setpoints. Nonlinear system analysis is applied to design and validate the controller. Two cases are tested: (a) the proposed four-leg inverter and (b) a standard three-leg inverter. The results show that the proposed controller rapidly mitigates CM disturbances while maintaining high-quality AC current waveforms in the four-leg configuration. Finally, the hardware performance of an SST prototype is evaluated. In particular, the ability of the SST to safely redirect and absorb CM currents is demonstrated, showing how it can protect neighboring conventional transformers in the system. The study confirms that appropriate control laws allow the SST to protect both itself and adjacent transformers during a HEMP or GMD event.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Applications of Solid-State Transformers for Electric Power Grid HEMP/GMD Resilience
A high-altitude electromagnetic pulse (HEMP) or geomagnetic disturbance (GMD) can disrupt power grids by inducing low-frequency common-mode (CM) currents. When these currents flow through grounded transformers, they can bias the magnetic core, driving it into saturation and reducing performance or damaging equipment. This work presents a solid-state transformer (SST) to replace vulnerable assets and improve grid resilience. The paper reviews half-cycle saturation in conventional transformers, then describes an SST architecture that neutralizes and redirects CM currents during HEMP/GMD events. A prototype SST is built and validated, demonstrating stable CM-disturbance operation and protection of nearby transformers. Finally, large-scale simulations show how coordinated SST deployment mitigates CM disturbances and strengthens overall grid resilience.
four-leg inverter↗
Advanced Electrical Materials and Components Being Developed
All aerospace systems require power management and distribution (PMAD) between the energy and power source and the loads. The PMAD subsystem can be broadly described as the conditioning and control of unregulated power from the energy source and its transmission to a power bus for distribution to the intended loads. All power and control circuits for PMAD require electrical components for switching, energy storage, voltage-to-current transformation, filtering, regulation, protection, and isolation. Advanced electrical materials and component development technology is a key technology to increasing the power density, efficiency, reliability, and operating temperature of the PMAD. The primary means to develop advanced electrical components is to develop new and/or significantly improved electronic materials for capacitors, magnetic components, and semiconductor switches and diodes. The next important step is to develop the processing techniques to fabricate electrical and electronic components that exceed the specifications of presently available state-of-the-art components. The NASA Glenn Research Center's advanced electrical materials and component development technology task is focused on the following three areas: 1) New and/or improved dielectric materials for the development of power capacitors with increased capacitance volumetric efficiency, energy density, and operating temperature; 2) New and/or improved high-frequency, high-temperature soft magnetic materials for the development of transformers and inductors with increased power density, energy density, electrical efficiency, and operating temperature; 3) Packaged high-temperature, high-power density, high-voltage, and low-loss SiC diodes and switches.
Schwarze, Gene E.↗
Design, Deployment, and Characterization of the World’s First Flexible Large Power Transformer
GE Research and its partner Prolec GE have designed, built and deployed in the field the world’s first flexible power transformer. The flexible power transformer is a transmission class 3-phase autotransformer configurable in impedance and in voltage which allows it to serve as a universal spare for multiple units in a given fleet. However, the key innovation in this new concept is the online adjustable leakage impedance which allows the transformer to change its impedance without interrupting the transmission line operation. The flexible power transformer can be designed with up to three low voltage transmission class ratings and up to 12 impedance values changeable both online and offline. This report provides an overview of the design, manufacturing, testing, and commissioning of the 165kV, 60MVA prototype built including the results of the field performance validation tests. The prototype was specified in collaboration with Cooperative Energy, the utility host. It was designed and tested in the factory according to IEEE standard C57.12.00 and followed all protocols for transportation, installation, and commissioning of a power transformer. In addition to the prototype, a flexible protection system capable of automatically adjusting its settings upon the transformer impedance was also developed and deployed in the for testing and validation. On September 3, 2021 the prototype was energized in Cooperative Energy’s substation in Columbia, Mississippi to become the world’s first flexible power transformer in operation. Its performances and impact on the grid operation were demonstrated through different field tests. Results obtained confirm that the impedance of the flexible transformer can be varied under load through its full range, from 4.3% to 9.3%, without adverse impacts on the line operation, the protection system, the transformer stability and health condition. Results also proved that the flexible transformer is very effective in controlling power transfer through the line or load sharing between units operating in parallel. Indeed, it was proven that higher impedances decrease the thruput power of the transformer while lower impedances increase it. Up to 26MW was controllable on a line loading of 45MVA. It was also possible to demonstrate that the variation of the transformer impedance has no effect on the circulating current between units in parallel, except a minor transient during the impedance change. It was also proven that the flexible protection relay can update its protection settings automatically when the impedance change was detected. The prototype has operated continuously for more than 12 months now with a peak load exceeding 50MVA corresponding to >80% of its ONAN power rating. No alarm, trip or sign of failure has been reported by the utility. In addition to the development and deployment of the flexible transformer prototype, investigations were carried out on new nanodielectric fluids to replace the mineral oil used in power transformers with the goal of reducing their footprint and weight. The key parameters that were targeted for improvement included the breakdown voltage to reduce clearances between windings and tank hence the footprint; viscosity and thermal conductivity to increase the cooling efficiency and therefore to reduce the winding material. Several nanodielectric mixtures with mineral oil including with alumina (Al2O3), titania (TiO2) and Borum Nitrate (BN) with different surfactants have been analyzed and tested. Unfortunately, despite encouraging results no nanofluid candidate has been found viable to replace mineral oil. With the formulations tested, breakdown voltages are generally similar to mineral oil at lower particle contents and worse at higher particle contents. Viscosity appreciably increased at particles concertation over 2 wt% and thermal conductivity increased slightly at 5wt% and appears to be 10-15% higher at 10 wt% particle content. It is recommended to continue investigations to find solutions that can help increase the power density of future flexible power transformers. Flexible power transformers can significantly help the future power grid by providing more flexibility and resiliency. Indeed, by providing voltage and impedance flexibility, flexible power transformers reduce the need for multiple spares, hence inventory costs for utilities. With their online controllable impedance, they can provide support to the grid and help manage short-circuit currents, power flow, line congestion, and grid stability which will become more important with higher penetrations of intermittent renewable resources. During the field validation tests, it was demonstrated that up to 26MW was controllable on a line loading of 45MVA when the transformer impedance was varied from its minimum to its maximum range. Also, with the impedance range, the short-circuit currents could be reduced by up to 38% at the load side of the transformer. With its controllable impedance, flexible transformers can be used in future strategies of grid resilience to help better prepare the grid to face forecasted severe events including storms, heat waves and contingencies. The flexible power transformers can also find role in other applications including high voltage transmission cables such as offshore wind farms where solutions for energizing the cables and managing the reactive power are of critical importance. The designed flexible power transformer is now fully validated and ready for commercialization. Further analysis on the benefits of flexible power transformers for grid stability and short-circuit management including current limiting capability, reclosure and line restoration, control of inrush current, sizing of flexible AC components (FACTS) would help its rapid adoption by the industry.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Mercury transformation processes in nature: Critical knowledge gaps and perspectives for moving forward
We report the transformation of mercury (Hg) in the environment plays a vital role in the cycling of Hg and its risk to the ecosystem and human health. Of particular importance are Hg oxidation/reduction and methylation/demethylation processes driven or mediated by the dynamics of light, microorganisms, and organic carbon, among others. Advances in understanding those Hg transformation processes determine our capacity of projecting and mitigating Hg risk. Here, we provide a critical analysis of major knowledge gaps in our understanding of Hg transformation in nature, with perspectives on approaches moving forward. Our analysis focuses on Hg transformation processes in the environment, as well as emerging methodology in exploring these processes. Future avenues for improving the understanding of Hg transformation processes to protect ecosystem and human health are also explored.
54 ENVIRONMENTAL SCIENCES↗
Design, Control, and Protection of a 13.2 kV, 1 MVA Solid State Transformer for Electric Vehicle Extreme Fast Charging Station
In this article, a medium-voltage (MV) ac-dc solid state transformer (SST) for electric vehicle (EV) extreme fast charging (XFC) station is proposed. The SST adopts a cascaded H-bridge (CHB)-based structure where the active front end (AFE) power stages are connected in input-series followed by dual active bridge (DAB) converters connected in an output-parallel configuration providing galvanic isolation through a high-frequency transformer (HFT). The SST is rated for 1 MVA and connects directly to a three-phase 13.2 kV MV ac grid through ac switchgear and outputs 750-V dc. At the dc bus, several dc/dc converters are connected, each of which can charge an EV based on its battery capacity. A novel decentralized control architecture of the SST is adopted in this work which simplifies the MV dc link voltage and module-level power balancing. In addition, the local and central protection designs of the SST are presented which identify and respond to the internal fault of the system. Finally, the experimental validations of the SST hardware prototype are presented up to the rated voltage. Furthermore, this article details the design and implementation of the MV SST addressing the challenges of an isolated MV class power converter for connecting directly to the MV ac grid with unique controller architecture, distributed protection framework, and SST constructional features.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Development of acceptance criteria for batches of silane primer for external tank thermal protection system bonding applications
Fourier transform infrared spectroscopy is currently the best technique for observing hydrolytic changes in DC 1200 silane the primers caused by moisture in the atmosphere. To further prove that FTIR can be used as a criterion test for acceptance of silane primer lots, intensities of the FTIR OH- band are being compared with primer adhesive bond strength using a mechanical test suggested by NASA. Results of tests for shear strength and Oh-absorption are tabulated and compared with FTIR absorption intensities in the OH-region.
Mikes, F.↗
Effects-Based Monitoring of Geomagnetically-Induced Current Using a Convolutional Neural Network
Geomagnetically-induced current (GIC) due to space weather can flow in the power grid causing undesirable effects such as transformer overheating, misoperation of protection devices, and potential blackouts. It is therefore important to monitor GIC in the power grid to improve online situational awareness and decision-making of system operators during a geomagnetic disturbance. To avoid the costly installation of GIC monitors at transformers’ neutrals, it is desirable to find correlations between GIC and already-monitored parameters. Hence, this work proposed the use of a convolutional neural network (CNN) to compute GIC amplitudes from learned patterns in the time-series data of transformer even harmonic currents. Using an electromagnetic transient program, GIC injection simulations were performed for a modeled Dominion Energy Virginia (DEV) substation with two 504 MVA, 500/230 kV transformers. Data collected from these offline simulations were used to train the CNN to provide online GIC monitoring. Testing the CNN performance involved using real GIC measurements from published literature and from a physical GIC monitor in the DEV area. Finally, the results showed that the proposed method was able to provide GIC readings with a root mean squared error of 1.56 A/phase (equivalent to an average accuracy of 94%) for these real GIC waveforms.
42 ENGINEERING↗
UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers
The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Impact Analysis of High-Altitude Electromagnetic Pulse Coupling Effects on Power Grid Protection Relays
Protection relays are important equipment used for protection, control, and metering functions in the power grid. These relays are used to protect critical and difficult-to-replace equipment, like generators, transformers, and capacitor banks. Once the protection devices are disturbed or damaged, a high risk of power generation interruption occurs. Therefore, it is important and necessary to study the relay’s immunity to electromagnetic pulse (EMP) events. As a preliminary step toward empirical experimentation on actual equipment, this manuscript outlines an economical and efficient methodology for evaluating the impact of an EMP. An impedance measurement strategy was employed to model the equipment, setting the stage for subsequent immunity analyses. These analyses included the pulse current injection (PCI) method, which utilized an injecting probe to introduce the transient, and frequency domain electromagnetic (FEKO) simulation, which integrated electromagnetic coupling effects into the transient simulation. The impedance measurement and simulation results in this paper provide a reliable basis for gauging equipment performance in the face of HEMP threats. The results obtained using the PCI and FEKO simulations demonstrated the performance of different port responses under a high-altitude EMP, indicating the requirement for some protection to ensure the reliable operation of relays.
42 ENGINEERING↗
INECP Country Engagement Plans and Transformational Events [Slides]
The International Nonproliferation Export Control Program (INECP) harnesses the expertise of the U.S. Department of Energy (DOE) national laboratories to assist partners internationally in implementing and adopting strategic trade control measures that can effectively counter WMD procurement efforts. This presentation includes discussion of work with LANL INECP technical leads to update the engagement plan for Turkey, which involved researching Turkey’s WMD related legal framework, relevant export control agencies, and WMD-relevant industries (e.g. advanced manufacturing and aerospace).
98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
Fabrication of Arrays of Topological Solitons in Patterned Chiral Liquid Crystals for Real-Time Observation of Morphogenesis
Topological solitons have knotted continuous field configurations embedded in a uniform background, and occur in cosmology, biology, and electromagnetism. However, real-time observation of their morphogenesis and dynamics is still challenging because their size and timescale are enormously large or tiny. Liquid crystal (LC) structures are promising candidates for a model-system to study the morphogenesis of topological solitons, enabling direct visualization due to the proper size and timescale. We report a new way is found to rationalize the real-time observation of the generation and transformation of topological solitons using cholesteric LCs confined in patterned substrates. The experimental demonstration shows the topologically protected structures arise via the transformation of topological defects. Numerical modeling based on minimization of free energy closely reconstructs the experimental findings. The fundamental insights obtained from the direct observations pose new theoretical challenges in understanding the morphogenesis of different types of topological solitons within a broad range of scales.
36 MATERIALS SCIENCE↗
3Y-TZP Toughened and Oxidation-resistant U 3 Si 2 Composites for Accident Tolerant Fuels
In this work, we report an innovative approach synergizing multiple effects of microstructure control, oxide protection and phase transformation-induced mechanically toughening to develop advanced U 3 Si 2 fuels with state-of-the-art materials properties. 3Y-TZP (3 mol% yttria doped stabilized tetragonal zirconia) additives are incorporated and uniformly distributed into the SPS-densified U 3 Si 2 fuel matrix, enhancing materials fracture toughness up to 4.04 MPa m 1/2 . The 3Y-TZP incorporated U 3 Si 2 composite pellets show significantly improved onset temperature of oxidation above 560 °C, which can be further improved to 617 °C with 3 vol% addition by post-sintering thermal annealing. We report the development of mechanically tough and oxidation-resistant U 3 Si 2 with minimal additive represents a major step forward towards realizing the potential of high density U 3 Si 2 as the leading fuel concept to increase accidence tolerance of nuclear energy systems.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Protective barriers and related methods
Corner assemblies for protective barriers for protecting assets (e.g., electrical power transformers and other substation components). The corner assembly includes two guide structures oriented perpendicular to each other. The corner assembly includes at least two protective member assemblies disposed within the two guide structures. Each protective member assembly includes two side members within protective members extending horizontally between the two side members.
Bratton, Kenneth R.↗
Environmental Protection Coating System for Refractory Metal Alloys (EPCS for RMAs)
As part of ARPA-E’s Ultra High Temperature Impervious Materials Advancing Turbine Efficiency (UITIMATE) program, this project aims to develop an environmental protection coating system (EPCS) for refractory metal alloys (RMAs) – which will provide radical improvement in long term protection for ultra-high temperature refractory metal components in harsh gas-turbine environments. The drive for higher fuel efficiency and higher core power of gas turbines used in electric power generation and in aircraft propulsion requires higher peak operation temperatures. The temperature capability of state-of-the-art materials cannot meet the new requirements. Refractory metal alloys have desirable capabilities for achieving the required peak temperatures, but most of them are subject to oxidation in the gas turbine environment. Thus, there is a strong need to develop novel environmental protective coatings that enable the refractory metals to operate in an ultra-high temperature engine environment. This project is composed of four major technical innovations that can provide a potentially transformational solution in providing environmental protection for refractory metal alloys over a wide range of temperature. 1) Multi-layer self-healing environmental barrier coating (EBC) that provides protection against combustion gas environment. 2) Oxidation resistant diffusion barrier (DB) on the alloy surface to enhance coating stability. 3) Synergistic integration of the multi-layer self-healing EBC with the diffusion barrier to extend coating life. 4) Guidance of physics-based modeling to accelerate coating development and optimization. Our team has successfully developed a multi-layer self-healing environmental protection coating system (EPCS) that can provide oxidation protection for commercially available molybdenum based refractory metal alloys over a wide temperature range of up to 1600 °C for fuel-efficient gas turbine applications. The team also developed a multi-layer high temperature coating design tool to accelerate coating development and optimization based on physics-based modeling. The team also engaged RTX business unite, notable Pratt and Whitney, for future commercialization of this technology. The successful completion of this Phase I effort led to the selection of performing Phase II of the program. In Phase II, the team plans to apply the EPCS in the protection of a newly discovered molybdenum-based metal alloy which has the potential of superior high temperature properties to the commercial products. Th coating will be evaluated under test conditions and environment that mimic gas turbine operation.
36 MATERIALS SCIENCE↗
New data-driven approach to bridging power system protection gaps with deep learning
Protection is a critical function in power systems to avoid equipment damage, maintain personnel safety, and support system reliability. However, current protective relay technology cannot adequately protect equipment and personnel from effects of some events; these deficiencies are termed protection gaps. In this paper, a data-driven approach is proposed to complement traditional protection technology and distinguish fault conditions from transients caused by normal operations. A combined convolutional neural network and long short-term memory (CNN-LSTM) network is implemented to achieve data translation invariance and capture the temporal correlation of the time-series input data. As a result, the data-driven method can accurately detect system faults despite variation and noise in the input data. In addition, using the CNN-LSTM--based method avoids the complicated, manual feature extraction procedure required by many traditional data-driven methods. The effectiveness of the proposed approach is tested on two kinds of protection gaps: high-impedance faults and transformer inter-turn faults. Lastly, a transfer learning method is also proposed to address the common issue of data-driven methods for which real-world training data are scarce. Extensive study results demonstrate that the proposed approach can accurately bridge power system protection gaps.
42 ENGINEERING↗
Preconceptual Designs of Coupled Power Delivery between a 4-Loop PWR and 100-500 MWe HTSE Plants
This study develops a preconceptual design for the integration between a large-scale high-temperature electrolysis facility and a NPP. Two hydrogen facility sizes are considered: 100 MWnom and 500 MWnom. Both steam supply designs use cold reheat steam extraction as a heat source. A reboiler inside the protected area of the power plant transfers steam heat to the demineralized water supply for the hydrogen plant. After the heat transfer, the extracted steam condenses and returns to the condenser while the process steam routes out of the protected area to the electrolyzers. Electrical power is tapped off from the high voltage side of the GSU transformer, where it is then transported via a 345-kV transmission line to the hydrogen facility. Circuit breakers and disconnects are located at both ends of the transmission line. Step down transformers and miscellaneous switchgear/buses are located at the end of the transmission line inside the HTEF boundary. Control capabilities for the steam interfacing equipment and electrical dispatch are accessible from the Main Control Room, and protective relays for the transmission line are located inside the Relay Room. Computer modeling was performed for the thermal and electrical designs. PEPSE analysis provided the steady-state parameters for thermal extraction from the turbine cycle. These parameters were used to inform transients and size equipment in combination with Applied Flow Technology (AFT) Arrow and AFT Fathom modeling for steam and water piping, respectively. Electrical transients were analyzed using PSCAD. An ETAP model was used to evaluate power flow and short circuit, which enabled the sizing of transformers and protective equipment. A cost estimate was developed for both integration designs when considering plant separation distances of 250 m and 500 m. From these estimates, the modifications for thermal and electrical interfacing of a first-of-a-kind nuclear-integrated hydrogen facility are anticipated to cost between $60–250/kWnom., where the subscript “nom” refers to the nominal size of the hydrogen plant. On a thermal power basis, the thermal power has a cost of approximately $8/MWth for a 500 MWnom high temperature electrolysis plant located 500 m distant from the NPP. That value decreases to approximately $7.5/MWth for a 250 m separation distance between the hydrogen plant and the NPP. This value is lower than previous estimates of the cost of heat extracted from NPPs primarily because in this work the steam is extracted from cold reheat instead of the main steam line, which reduces the cost of the dispatched steam by approximately $3.5/MWth. Nuclear steam extraction can provide a profit avenue for many plants and is not restricted to hydrogen production. Ammonia production, oil refining, and paper production, among other industrial processes all require thermal energy, which can be provided by NPPs. Future work should look further at the details of thermal extraction for a variety of use cases. This can include increased levels of extraction and multiple simultaneous users. Additionally, site-specific studies should be performed to develop industry experience and improve cost accuracy.
08 HYDROGEN↗