progress with pops
DESCRIPTION
Progress with POPS. Jean-Paul Burnet TE/EPC. IEFC workshop, Feb 2010. POPS What is it?. POPS will feed the PS main magnets. It’s a completely new power system. It will replace the present powering system: - Siemens motor-generator - transformers and thyrsitor rectifiers - PowerPoint PPT PresentationTRANSCRIPT
Progress with POPS
Jean-Paul BurnetTE/EPC
IEFC workshop, Feb 2010
POPS What is it?
POPS will feed the PS main magnets.
It’s a completely new power system.
It will replace the present powering system:- Siemens motor-generator- transformers and thyrsitor rectifiers- control systems
Main difference: rotating machine versus static converter!
2
Why replacing the present power system?
Single point of failure of the LHC injector chain!
Any fault on the rotating machine can lead to LHC stop for weeks!- no spare rotors nor stators, see ATC/ABOC days 2007- Ageing machine suffering of mechanical fatigue
3
Why replacing the present power system?
A human error can also generate many weeks of repair.
Just forget to put back the motor brushes and you create 10 kA short-circuit and arcs on the collector. We needed three weeks to repair with the help of Siemens.
4
Example of repair, 2010
5
Example of repair, 2010
6
Example of repair, 2006
7
Broken fan blade
Failure of the spare rotor (insulation)
Present situation regarding spares
Lot of components are available as spares.But only the 13MVA transformer can replace the rotating machine in degraded-mode.
LHC Cycle can be done in 6s (instead of 3.6s)Only 4 cycles / minute can be done (instead of 16)
LHC program can be done with the 13MVA but nothing else.
We ran the PS for the AMS tests (February 2010) with the 13MVA transformer.
26 GeV/c tested in 2006 without beam26 GeV/c tested with beam in 2009
8
POPS Planning
Contract signed on December, 17th 2007 with Converteam
Original planningJanuary – December 08: Design CVT & CERNDecember 08 – April 09: Civil engineering worksJune 09: First delivery from ConverteamJune – September 09: Installation CVTOctober 09: CommissioningNovember – December 09: First test with PS machineMarch 2010: POPS in operation
Since we have no shut down in 2010
January 2010 – April 2010: Commissioning on dummy load10 SPS magnets (MBE) 0.1H instead of 1H, at full current (6kA)
March 2011 ? Test on PS magnets April 2011 ? POPS in operation
9
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
• DC/DC converters transfer the power from the storage capacitors to the magnets.• Four flying capacitors banks are not connected directly to the mains. They are charged via the magnets• Only two AC/DC converters (called chargers) are connected to the mains and supply the losses of the system.
Chargers
The energy to be transferred to the magnets is stored in capacitors
• Classical polypropylene dry capacitors 2mF/5kV, 126 cans (80kg) per bank• Six outdoor containers, 18 tons, 40 feet (total value 1.48F)• Medium Voltage Drives• Turnkey system• • Main losses:
• 180kW in air• 600kW water cooled
Flying capacitors
POPS: Power system based on capacitive storage
PatentThe global system with dedicated control has been filed as a patent application. European Patent Office, Appl. Nr: 06012385.8 (CERN & EPFL)
10
POPS basic principle
Magnets current and voltage Voltage and current of the magnets
-10000
-8000
-6000
-4000
-2000
0
2000
4000
6000
8000
10000
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Temps [s]
U [V]I [A]
Active power of the magnets
-60000000
-40000000
-20000000
0
20000000
40000000
60000000
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Time [s]
Pow
er [W
]
.
Inductive Stored Energy of the magnets [J]
0
2000000
4000000
6000000
8000000
10000000
12000000
14000000
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Time [s]
Ener
gy [J
]
.
Capacitors banks voltage
0
1000
2000
3000
4000
5000
6000
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Time [s]
Volta
ge [V
] .
Resistive Losses and charger power
0
2000000
4000000
6000000
8000000
10000000
12000000
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Time [s]
Pow
er [W
] .
Losses
Power to the magnets
Stored magnetic energy
Capacitor banks voltage Power from the mains
+50MW peak
5kV to 2kV
12MJ
10MW
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
11
POPS numbers
POPS required: 600 kW cooling tower 170 kW air-conditioning 200 m2 indoor 800 m2 outdoor 10 MVA on the 18kV network (3 switch-gears) 700 kVA on the 400V network
12
POPS budget:
Converteam: 9.23 M€ + 1.05 M€ (spares & maintenance for 5 years)
Infrastructure: 3 MCHF + …(25% civil engineering, 30% cooling ventilation, 17% electricity)
POPS outdoor layout
13
End of the construction
14
Outdoor
End of the construction
15
Outdoor
POPS indoor layout
16
End of the construction
17
Indoor
POPS infrastructure
During the infrastructure works, we discovered progressively that the building needed an upgrade:
New fire detection New walk ways close to the ceiling to access the lightning & fire detection New lighting system New platform for crane maintenance New AUG chain New smoke extraction ….
Last discovery: the roof has to be “consolidated”. GS will take care of it, 500kCHF!
18
POPS water cooling system
POPS required a water cooled circuit of 600 kWEN/CV installed a dedicated cooling tower
Cooling pipes completed, X-ray testedWater cooling system is now operational
19
POPS ventilation
POPS required 170 kW of air conditioning
Ventilation system is operational
20
For both systems, it is impossible to commission at full load without the PS magnets.
POPS dummy load
TE/ABT hangar has been transformed as a magnet test bench
21
10 SPS magnets (MBE)5kA peak10 mH
POPS commissioning
22
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying moduleAll converters installed.
All cooling units filled up and running. All power cables tested. All auxiliaries tested.
Power tests started beginning of January 2010The commissioning will be done on a dummy loadPeak current: 6kA (to be negotiated with MSC)Rms current: 1kA1/10 of the nominal energy (1.25MJ/1.8MJ instead of 12MJ)
AFE1Tr1
DSP1
DCP1
DC3
DC1
DC5
DC4
DC2
DC6
MAGNETS
CB3
CB2
CB4L1
MAGNETS
L2
CF11
CF12
CF1
CF21
CF22
SWB2
SWB1SW3
SW1
AC1
MV7308
AC2
MV7308
S = 2.5 MVAU20 = 1950V
TRANSFORMER N°2
Premagnetisation - PrechargeTRANSFORMER
S = 2.5 MVAU20 = 1950V
TRANSFORMER N°1
400V AC2x250A
Premagnetisation - PrechargeTRANSFORMER
OF1 OF2 SW4
SW2
SW6
SWC1SWC2
SW5
RF1 RF2
Rlim2Rlim1
Lf1 Lf2
Not part of the specification
Not part of the specification
Not part of the specification
Kp22Kp12
TW1TW11
Lw1
TW2
TW21
Lw2
Kp11 Kp21
Earth switch
selection
200 Ohms
SWA1
SWA2
Crwb1
Crwb2
18KV ACScc=600MVA
Not part of the specification
CB1 CB3 CB2
18kV/100V
CF2
S =
2.5
MV
AU
20 =
195
0V
TRAN
SFO
RM
ER
N°3 DJ1 DJ2
CB1
CB5 CB6
+
-
+
-
+
-
-
+
-
+
-
+
DC1
PIB
310
PIB
102A
PIB
100G P
IB31
0
PIB
310
PIB
102A
PIB
100G P
IB31
0
AC1
PIB
310
PIB
102A
PIB
100G P
IB31
0
TIB
CP
U
Keypad
DC3
PIB
310
PIB
102A
PIB
100G P
IB31
0
PIB
310
PIB
102A
PIB
100G P
IB31
0
DC5
PIB
310
PIB
102A
PIB
100G P
IB31
0
PIB
310
PIB
102A
PIB
100G P
IB31
0
AC2
PIB
310
PIB
102A
PIB
100G P
IB31
0
TIB
CP
U
Keypad
DC2
PIB
310
PIB
102A
PIB
100G P
IB31
0
PIB
310
PIB
102A
PIB
100G P
IB31
0
DC4
PIB
310
PIB
102A
PIB
100G P
IB31
0
PIB
310
PIB
102A
PIB
100G P
IB31
0
DC6
PIB
310
PIB
102A
PIB
100G P
IB31
0
PIB
310
PIB
102A
PIB
100G P
IB31
0
FGC
MAIN CONTROLER
PA
L
C
PU TIB
PIB
310
P
IB10
0GP
IB10
2A
PIB
310
PIB
310
Crowbar
TIB
TIB
TIB
P80i
1 2 34 5 6
7 8 9101112
AB
12 x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
Ethe
rnet
A
1 2x
6x
8x
2x
9x
3x
10x
4x
11x
5 x
7x
1x
C
SCADAControl
C
PU
Process
POPS electrical schematic
POPS commissioning
24
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
First, the power transformers (2.5MVA)
Sepam software tested successfully. Power cables tested, Auxiliaries tested.
Tr1 and Tr2 tested at no load. Maximum Inrush observed 7.5*In
Still to be done:Heat run (impossible without the load!)New transformer Roofs to be installed due to leakages
POPS commissioning
25
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
Test of the capacitor banks individually
Capacitor charged up to 4.2kV with an external power supplyDischarged through the 96 ohm resistance. Max resistor ΔT 140ºC
POPS commissioning
26
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
Test of AFE with a capacitor bank
Power up procedure completed on AFE2 + DCP2 + DSP2Tests done last week
30s 16s
Precharge with limiting resistor
Precharge without limiting resistor
C B closed and AFE modulating
VdcVdc+; Vdc-
Id
POPS commissioning
27
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
Next steps
Power up AFE1 + DCDC1 + DSP1 + magnetsPlanned week 7 - 8
Power up AFE1 + DCP1+ DSP1 + DCP3 + DSP3 + magnetsPlanned week 9
Power up AFE1 + DCP1+ DSP1 + DCP3 + DSP3 + DCP5 + DSP5 +
magnetsPlanned week 10
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
POPS commissioning
28
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
Next steps
Power up AFE2 + DCDC2 + DSP2 + magnetsPlanned week 11
Power up AFE2 + DCP2+ DSP2 + DCP4 + DSP4 + magnetsPlanned week 12
Power up AFE2 + DCP2+ DSP2 + DCP4 + DSP4 + DCP6 + DSP6 + magnets
Planned week 13
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
POPS commissioning
29
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying moduleFinal steps
Full power test: week 14 (10 April)
Final reception tests: planned week 14
POPS control
POPS will be controlled by a FGC as now for the MPS.
For the cmd & status, EN/ICE will provide a HMI done with PVSS.
CCC will have to use both system.
Bloop as today.
Postmortem with FGC.
CVT will change the optic fiber cable (too fragile) after the final tests
30
POPS operation
How POPS will not be a single point of failure?
No unique device!POPS is modular and redundant
POPS can work with : Only 1 transformer over 2 (rms magnet current reduced by 40%) Only 1 AFE over 2 (rms magnet current reduced by 40%) Only 5 DCP over 6 only 5 DSP over 6
31
POPS operation
How POPS will be safer than MPS?
POPS has a complete key locking system for doors and mechanical switches
The configuration will be set by the HMI The key locking system will authorize
operation The grounding is done with mechanical
switches managed by key locking system
32
POPS versus MPS
DC3
DC
DC +
-
DC1
DC
DC
DC5
DC
DC +
-
DC4
DC
DC-
+
DC2
DC
DC-
+
DC6
DC
DC
MAGNETS
+
-
+
-
CF11
CF12
CF1
CF21
CF22
CF2
AC
CC1
DC
MV7308
AC AC
CC2
DC
MV7308
AC
18KV ACScc=600MVA
OF1 OF2
RF1 RF2
TW2Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFEDC/DC converter - charger moduleDC/DC converter - flying module
Time from injection to flat-top = 500ms instead of 650ms with MPS
Magnets current and voltage I - U Magnet
15.00k
-15.00k
0
-10.00k
-5.00k
5.00k
10.00k
0 2.40500.00m 1.00 1.50 2.00
POPS can go faster than MPS: 26GeV/c cycle can be done in 1.2s!
But the main limitation remains the RMS magnet current
POPS is designed for an equivalent RMS magnet current of 3.2kA
Still to be done: The DC connection to the magnets
The problematic: Cross the PS tunnel!
POPS, what is missing?
34
Constraint: No access during PS operation
Hypothesis: Don’t touch the PS tunnelno civil engineering over the tunnel
Solution: The bridge
The cost: over 1 MCHF
24M long
Total length 80m 35
POPS, what is missing?
Review the hypothesis: dig over the PS tunnel
Make a cable ductPlace classical cable inside
8 cables (240mm2) per polarity * 4 = 3km of cable
To be agreed with GS/SEM et PS landlord?
Don’t show this to Lucio!
36
DC link, cost killing
Commissioning is ongoing.
Final reception tests with Converteam planned in April 2010.
Still to be done: the DC link to the PS magnets
Define the DC link solution Launch the purchasing of the material Prepare everything as possible in advance
DC link can be done in a shut down of at least 2 months
If the MPS has no problem during this run, POPS will be commissioned on the PS magnets after the next shutdown, 2011 ? 2012 ?We already bought one more year of warranty (up to end of 2012)
If POPS has to start earlier, the cables can be put on ground in 2 weeks + 2 weeks of commissioning on load with CVT & CCC
POPS, what else?
37