Intermagnetics Plays Key Role in Developing Revolutionary
Electric Power Transformer
Thursday May 21, 12:00 pm Eastern Time
Company Press Release
SOURCE: Intermagnetics General Corporation
Intermagnetics Plays Key Role in Developing Revolutionary
Electric Power Transformer
Lighter, Safer, More Durable Unit Proves Feasible For Large-Scale Commercial
Applications
LATHAM, N.Y., May 21 /PRNewswire/ -- Intermagnetics General Corporation (Amex: IMG - news)
today announced that it designed and manufactured key components for a breakthrough superconductor
transformer that has been successfully tested by a U.S. industry team of scientists and engineers and
demonstrated to be feasible for large-scale commercial applications.
''This is an important breakthrough in electric power technology -- a new type of power transformer that
will be much smaller, lighter and safer, while having a much greater life expectancy than conventional
transformers,'' said Carl H. Rosner, chairman and chief executive officer of Intermagnetics. ''In addition,
these new transformers do not contain the thousands of gallons of insulating cooling oil that pose a
potential fire and environmental hazard in conventional transformers. All of us on the development team
are committed to commercializing this exciting new product.''
The team of engineers and scientists, led by Waukesha Electric Systems, also announced that the smaller
size and up to two-times emergency capacity without reduction of transformer life will result in greatly
reduced transformer cost per unit of power delivered and more power per unit area in existing,
limited-space substations. The test of the 1 MVA (Mega-Volt-Ampere) version confirmed the technical
feasibility and advantages of scale-up to larger units such that the weight will be 24 tons rather than the 48
tons for a conventional 30 MVA power transformer typical of the largest segment of the power
transformer market. (Note that 30 MVA is the equivalent of 30 megawatts of power delivered into various
types of energy-storing/energy-consuming loads. One megawatt will light ten thousand 100 watt light
bulbs.)
Two differences in design that make the new transformers revolutionary are high temperature
superconductor (HTS) materials, instead of copper windings, and a relatively small refrigeration system
which replaces the very large heat exchangers of the conventional oil-filled power transformer. The 30
MVA HTS transformer will require approximately 200 pounds of superconductor, which has no electrical
resistance and, therefore, directly generates no heat, as compared to many thousands of pounds of
copper, which, though low in resistance, is still a major source of heating and electrical losses. The
Waukesha Electric System HTS transformer approach is unique in its use of closed-cycle cryocooling of
the transformer windings to temperatures as low as 382 degrees below zero, Fahrenheit (F), to more
effectively use any of a variety of candidate HTS conductors, each at a temperature optimum for its
performance in a trade-off with refrigeration costs. Commercial cryocooler refrigeration technology is well
established.
The nominally 1-MVA experimental HTS transformer has been constructed as a testbed for the
evaluation of various innovative components. To minimize steps for subsequent scale-up, this transformer
has an iron core, tank (overall steel enclosure) and winding cross section comparable in size to what
would be used in a commercial 30-MVA HTS transformer. However, as an experimental device, it
contains a relatively small amount of superconductor and is designed to operate as single phase rather than
three phases.
By either of two commonly used measures, this experimental unit can be considered the most powerful
superconducting transformer constructed to date, worldwide. In brief tests, the transformer was energized
to 11,000 primary volts and, separately with augmented cooling, to 150 primary amperes (over twice its
nominal rated current) for an indicated power delivery capability of 1.65 MVA (volts x amperes = MVA,
millions of volt-amperes). The transformer was also driven to the maximum power available at the test
site, delivering over 0.68 MVA of actual power to a large capacitive load (that is, simultaneously carrying
150 primary amperes at 4,500 primary volts). The basic technical feasibility of the cryocooled approach
was confirmed and target winding temperatures below -382 degrees F were achieved. However, with its
single cryocooler, this experimental transformer was not designed to handle on a steady-state basis, the
increased thermal load caused by operation to these high current levels, and so continuous operation of
the transformer was demonstrated only at lower levels of current and power.
The same team that built and tested the 1-MVA HTS transformer will further modify it in support of a
follow-on multi-million dollar conceptual design and construction of a three-phase 5/10 MVA alpha
prototype transformer, which, as part of its evaluation, will power the Waukesha main transformer
manufacturing plant.
Key to the success of this program is the combined expertise of the carefully selected group of team
members led by Waukesha Electric Systems (WES) of Waukesha, Wisconsin - the leading manufacturer
of power transformers in the U.S. and one of the nation's foremost producers of modular substations and
surge arresters serving electrical utilities and industrial firms. WES was responsible for the design and
construction of the 1-MVA transformer core and tank and overall transformer assembly and test.
Intermagnetics General Corporation (IGC) of Latham, NY is a leading developer and manufacturer of
low-temperature (LTS) and HTS superconducting magnets, wire and cable and associated
low-temperature refrigeration equipment. IGC was responsible for overall 1-MVA design and project
integration, part of the cryosystem design, and design, development and manufacture of the HTS
conductor and transformer windings. Oak Ridge National Laboratory (ORNL), Oak Ridge, TN is a
federally funded research institution managed by Lockheed Martin Energy Research for the U.S.
Department of Energy. ORNL had major responsibility for the design, construction and operation of
winding support, cooling and cryogenics subsystem. Rochester Gas and Electric Corporation (RG&E) is a
public utility located in Upstate New York. RG&E provided monetary support and commercial application
design support. Advice and supporting analyses were provided by internationally recognized consultants
from the Electric Power Engineering Department at RPI. This 1-MVA project was partially supported by
the U.S. Department of Energy (DOE) Superconducting Technology Program through the ORNL
Superconductivity Technology Center.
The team is committed to commercialize HTS transformers after the follow-on program, based on a
Product Development Agreement between WES and IGC.
Dr. Christine Platt at the U.S. Department of Energy Office, remarked on the importance of the success
of the HTS transformer test by the Waukesha team, further commenting that as much as 8% of electricity
generated by power plants is now lost in the process of electricity delivery. Power transformers account
for one-half of this loss, and superconducting materials and products can cut that loss by half, thus
reducing the amount of fuel burned to generate electricity and correspondingly reducing the cost of
electric power and its affect on the environment. ''The Waukesha-led team has demonstrated a
breakthrough technology with the potential to save Americans hundreds of millions of dollars each year in
electricity costs,'' she said.
Bob Jones, Senior Engineer, Rochester Gas and Electric Corporation stated: ''High Temperature
Superconducting Transformers are attractive to RG&E because they are much smaller, have greatly
extended overload capability and don't have fire and environment problems associated with transformer
oil. Our typical substations are designed with two transformers. If one transformer fails, its mate must be
able to carry the load of both. This means in a conventional substation there is a considerable amount of
unused transformer capacity. An HTS transformer can carry up to 200 percent of its nameplate rating
indefinitely so it can be sized to more closely match the expected load. The bottom line is we will be able
to pack up to four times the transformer capacity into the footprint of a conventional transformer. HTS
transformers promise to bring sweeping changes to transformers and substation design.''
According to Bob Hawsey, Superconductivity Program manager for ORNL, ''The successful
demonstration of this new transformer technology is one of the highlights of ORNL's industry partnership
activities this year. Part of the testing confirmed the basic technical feasibility of a unique ''cryocooled''
approach. For this, the target winding temperatures near 25 K are achieved using a single cryocooler and a
novel cooling route to remove heat from the windings. We're excited to be a team member for the
Superconductivity Partnership Initiative project to develop a pre-commercial, 5-MVA prototype, as well,''
added Hawsey.
Intermagnetics is the largest integrated developer and manufacturer in the United States, of
superconducting LTS and HTS magnets, wire and cable as well as associated low-temperature
refrigeration equipment, and radio-frequency (RF) coils, the combination of which is essential to
successful application of superconductivity such as Magnetic Resonance Imaging (MRI). The Company is
dedicated to the development and commercialization of applied superconductivity and refrigeration
systems. The Company also supplies permanent magnet systems, materials separation equipment and
FRIGC(R) refrigerants as replacements for ozone-depleting refrigerants.
SOURCE: Intermagnetics General Corporation
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