Consolidation programSPS Main Power Converters

(Dipole & Quadrupole)

K. Kahle / Q. King / G. Le Godec (TE-EPC)

IEFC Workshop, 9 March 2012

o SPS consolidation overviewo Transformerso Thyristor bridgeso Electronics and CISo Powering testso Conclusions

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Outlines

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Consolidation overview

Overview

SPS Dipole Circuit

Power system ratings: 25 kV/6kA/150 MW 12 converters connected in series 2 active spares.

18 kV

+15°

-15°

+15°

-15°

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OverviewS

pare

s

2 converters

1 active spare

18 kV

+15°

-15°

+15°

-15°

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Overview

SPS Quadrupole Circuit

Power system ratings: 4.8 kV/2.2 kA/ 10.6 MW 2 converters + 1 active spare

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History of SPS powering

1975: SPS Main Power System was put into service,

1981: Transformer upgrade for collider mode (voltage increase),

1993: Change of the regulation control electronics

1998: Replacement of the command and interlocking system (CIS)

1998-2000: Filter capacitors replacement (PCB elimination),

2002: New Earth Protection and Discharge System (Crowbar),

The consolidation program shall continue to maintain the excellent availability of the machine

Overview

SPS powering consolidation: A large project!

18 kV

+15°

-15°

+15°

-15°

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Overview

18kV cablesQty 20 km

LS1 EN/EL

Transformers

Qty = 68LS1

TE/EPC

ThyristorsQty = 68

LS1TE/EPC

Electronics and CIS

LS1-2TE/EPC

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Overview

Strategy: For the case of major problem, we shall be able to

return to the previous situation.

Transformers: Full compatibility between old and new transformers (dimensions of the pits and power connections),

Thyristor bridges: Full compatibility between old and new thyristor bridges (no modification of existing converter racks),

18 kV cables: Keep the ability to reconnect the old cables. Feasibility study underway (EN/EL).

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Transformers

For SMD and SMQ

Transformers

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Oil Transformers … reasons to change Ageing (≈30 years of operation):

High maintenance costs and urgent need of consolidation:o Corrosion,o Oil leakages.

PCB traces Oil treatment in 2008-2009 to conform to French/Swiss

regulation, However, traces of PCB remain (within the legal limit <50ppm),

The oil transformers will be replaced by cast-resin transformers during LS1: 60 transformers in 30 enclosures (6 MCHF).

Transformers

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Transformers

Existing oil transformers

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Transformers…

Transformers

4 pre-series transformers already in operation in 2011,4 additional transformers installed for the operation in 2012,

Transformers

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Preparations in 2012…

The SAX area will be required for the storage of the new cast-resin transformers in 2012-2013,

The old oil transformers need to be stored on platform with oil retention (b.951) until 2016.

Clear out of all equipment is required

Presently, the SAX area is managed by GS. We would like to take the responsibility for this area as it was designed to store oil transformers.

Transformers

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Preparations in 2012…

Access road around BA2 to be rebuild (budget 55 kCHF covered by GS),

Transformers

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Installation in 2013… Installation of 60 transformers by TE-EPC (January - December

2013), The installation per converter (4 transformers) takes 10 days, The pre-tests without power take 4 days,

The support of the following groups is required: EN/HE for transport and crane, EN/EL for the control cabling and earthing system,

Planning proposal

The coordination and the planning of all co-activities is required with the support of the SPS coordination team.

BA1 January 2013

BA2 February – March

BA3 April – May

BA4 June

BA5 September

BA6 October

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Thyristor bridges

For SMD and SMQ

Thyristors

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Thyristors … reasons to change

Expected lifetime of all components is reached: Increasing problems with reliability of operation (water leaks,

issues with electrical contacts, thyristor firing circuits etc…)

The old bridges will be replaced during LS1: 68 thyristor bridges in

17 power converters (1 MCHF).

Thyristors

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Thyristors

Thyristors: existing water-cooled power

bridges

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Thyristors…

Thyristors

Integration into the existing racks

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Thyristors…

Thyristors

Two parallel bridges

Replaced by one single bridge

Thyristors

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Preparations in 2012…

Delivery of prototypes (Dipoles & Quadrupoles) in July 2012,

Mechanical validation in a spare converter (outside SPS),

Installation of 2 thyristor bridges in BA2 spare converter in September for validation with the SPS,

Operation with this spare converter until end of 2012,

Delivery of all bridges in 2013.

Thyristors

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Installation in 2013…

Installation of 68 bridges by TE-EPC from January to December 2013, The installation per power converter takes 6 days, The pre-tests without power take 2 days,

No co-activities with other groups

Planning proposal BA1 January 2013

BA2 February – March

BA3 April – May

BA4 June

BA5 September

BA6 October

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Electronics and CIS

Electronics and CIS

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Electronics… reasons to change Increasing problems with reliability of operation (connectors,

contacts, etc…),

Modern diagnostics tools are needed to optimize performances and post mortem analysis,

The consolidation of Electronics is a long term project and will be completed in LS2.

Electronics

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Electronics…

Electronics

Electronics designed by S. Van Der Meer

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Electronics

AnalogueVoltage

Regulation

Powerpart

AnalogueCurrent

Regulation

FunctionGeneration

DAC

MUGEF in 2012

I ref Vref

I meas

V meas

AnalogueVoltage

Regulation

Powerpart

AnalogueCurrent

Regulation

Func.Gen.

DAC

MUGEF after LS1

I ref

Vref

I meas

V meas

ADC

DigitalCurrent

Regulation

Analogue regulation can be reactivated in minutes

First step: integration of Current Regulation in the Mugef in LS1.

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The new MUGEF software will provide many benefits including post-mortem logging, asynchronous starting and stopping of the SPS mains (no need for a special supercycle) and digital regulation of current.

Digital regulation in the new MUGEF software uses the same regulation library (Libreg) as the FGCs in the LHC, POPS and Booster.

Digital regulation will improve the tracking of the reference, management of current and voltage reference limits and monitoring of the regulation error.

Electronics

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Command and Interlock System (CIS)

CIS

HMI (BA3)

Master PLC (BA3)

Local PLC’s (all BA’s)

Local PLC’s (all BA’s)

Local PLC’s (all BA’s)…

Modernization of the CIS system

Reprogramming of new PVSS for CIS was not yet successful.

We had to return to the

old HP workstation

First phase

Second phase

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Powering tests

Powering tests

Powering tests

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System tests at the end of LS1

By the end of LS1, all 18 kV cables, all transformers, all thyristors, part of the regulation system will have been replaced: comprehensive tests of the entire system are required before physics can re-start.

Power tests of the entire system: SPS ring closed at the end of February 2014, First beam in the SPS beginning of June 2014, Requirement EPC: 2 months of powering tests in March-April 2014,

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Conclusions

Conclusions

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Manufacturing of transformers and thyristor bridges underway,

Pre-series transformers have been validated in operation,

Pre-series thyristor bridges will be validated in operation in September,

Some preparations still need to be done in 2012 (SAX area, civil eng. BA2),

In case of major problems, we can always return to the previous situation,

Power test period is required,

All old transformers and thyristor bridges will be kept for at least 1-2 years as a backup,

Proposal to transfer the management of the SAX area to EPC,

Conclusions

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Thank you…