Power Converters, water cooled cables and warm bus bars

Power Converters and DC cables Slide 1/..LHC - HC review Hugues THIESEN – AB/PO Thursday, 12 May 2005

Water cooledcables

warm bus bars

powerconverter

Energy Extraction


IntroductionIntroduction

1. Power converter reception tests and installation2. DC cable reception tests and installation3. Warm power tests without superconducting magnets4. Cold power tests with superconducting magnets5. Conclusion


LHC Power ConvertersLHC Power Converters

TI 2

TI 8

SPS

Injection

Injection

Beam dump

SR1BA7

BA4

RR13RR17

UJ14UJ16

UA23

UA27

SR2

UJ33

SR3

UA47UA43

SR4 RR53 SR5

SM18

RR57

USC55UJ56

UA63

UA67

RR73SR7

RR77

SR8

UA83

UA87

SR6Point 5

Point 4

Point 2

Point 3

Point 6

Point 7

Point 1

Point 8

SR: Thyristor PCs forthe warm magnets

ARC: 60A corrector PCs

UA: 3.25kA and 2kA PCs600A and 120A PCsMB PCs

RR: 2kA PCs600A PCs

•1700 converters with 98% underground

• 750*60A corrector converters (0.5kW)

• 740*120A&600A converters• 220*2kA&3.25kA converters• 8*13kA MB converters (2.6MW)


LHC Power Converter

DcctFGC

Vref

Magnet

Power Part(Voltage Source)

AC Mains Supply

DC cables

Power Interlock Controller

Cooling System

WorldFIP(Iref)

DC cables Intk

LHC Power ConvertersLHC Power Converters


Power converter tests before installation

Power Part(Voltage source)

FGC

Dcct

Individual Testsat CERN

Surface Halls

Individual Testsat manufacturer

premises

Power Part(Voltage source)

FGC

Dcct

Power Part

FGC Dcct

Converter Integrationat CERN

Surface Halls

LHC Power Converter(Current source) :

Performance validation

Power converter reception testsPower converter reception tests


PC installationPC installation

Power converters installation

•the power converters are transported and installed in the tunnel without to be dismantled…


PC installationPC installation

… except the main dipole power converter

11 m

2.2 m

Installation tests

40 t

- By the specialists- In parallel with the short circuit tests

Power converters installation


DC cables Installation and testsDC cables Installation and tests

Water cooled cable tests and installation

•The water cooled cables are not tested at CERN before their installation

•After their installation, the water cooled cables are only tested

•in pressure : 24 bars, 10 minutes

•in insulation : 3 kV DC with current leakage measurement


Powering circuitPowering circuit

Energy Extraction

PowerConverter

Magnet

Intksyst

CtrlRoom

DC cables

ACMain

supply

DC cable intk

Cooling system

Warm power tests (EDMS 464458 & 573115)

Cold power tests (EDMS 519716)


Warm power testsWarm power tests

8 hours heat run tests for superconducting circuits•The objectives of this test are to valid

• AC connexion of the power converter• Installation of power converter• Cooling of the DC cables• DC connexions between power converter, DC cables and

discharge system

•The magnet is replaced by a short circuit piece

Hardware commissioning procedureEDMS 575406



8 hours heat run tests for superconducting circuits

•Requests• AC distribution• UPS• Water cooling system• Ventilation system• Short circuit pieces

• Energy extraction system for the 13kA and 600A with EE• PIC for the 13kA



8 hours heat run tests for warm magnets

•The objectives of this test are to valid• AC connexion of the power converter• Installation of power converter• DC connexions between power converter, DC cables and

magnet• Set up of the current loop• Power converter performance

•For transfer line power converters, the TI8 procedure is used



•Requests• AC network• Interlock system• Magnet

8 hours heat run tests for warm magnets



Interlock tests

•The objectives of this test are to valid•Connexion between the interlock system and the power

converter•Comportment of the different system (power converter,

interlock system and energy extraction system)

Control Test

•The objectives of this test are to valid• The WorldFIP (MUGEF for TL-PC)• The Field Control Room softwares• The Alarm system, Logging system and Post Mortem system


24 hours heat run test for superconducting circuits

•The objectives of this tests are to valid• Global water cooling system• Global air conditioning system• Global AC distribution• Global control of power converters by the FCR



Warm power testsWarm power testsID Task Name Duration

1 Power Converter Short Circuit Tests 58 days

2 UA83 40 days

3 Water connection 1 day

4 400V and UPS connection 1 day

5 RB 14 days

6 Converter reception tests 8 days

7 18kV connection 1 day

8 PIC connection & Discharge system verification1 day

9 Converter setting 1 day

10 8H Heat run 1 day

11 DCCT calibration tests 2 days

12 RQD, RQF 7 days

13 PIC connection & Discharge system verification1 day




17 Other converters 6 days


19 8H Heat Run sector D2C 1 day

20 Test des systemes de decharge secteur C2B1 day

21 Converters setting sector C2B 1 day

22 8H Heat Run sector C2B 1 day

23 Converters setting sector B2A 1 day

24 8H Heat run sector B2A 1 day

25 PIC connection 1 day

26 Inner Triplet 8 days

27 Converters reception tests 3 days





32 WorldFIP connection for the UA83 2 days

33 24H Heat Run for the UA83 1 day

34

35 RR77 8 days

36 Water connection 1 day

37 400V connection 1 day

38 Discharge system tests 1 day


40 8H Heat Run 1 day


42 WorldFIP connection 1 day


44

45 Tunnel machine sector 7-8 10 days

46 400V connection 2 days

47 Converter setting 3 days

48 WorldFIP connection 4 days


AB-PO

AB-PO,TS-EL

AB-PO,AB-CO,AT-MEL

AB-PO

AB-PO,TS-EL,AT-MEL

AB-PO

AB-PO,AB-CO,AT-MEL

AB-PO

AB-PO,TS-EL,AT-MEL

AB-PO

AB-PO

AB-PO,TS-EL

AB-PO,AB-CO,AT-MEL

AB-PO

AB-PO,TS-EL,AT-MEL

AB-PO

AB-PO,TS-EL

AB-PO,AB-CO

AB-PO

AB-PO

AB-PO,TS-EL

AB-PO

AB-PO,AB-CO

AB-PO,AB-CO

AB-PO,TS-CV,TS-EL,AT-MEL,AB-CO

AB-PO,TS-CV

AB-PO,TS-EL

AB-PO,AT-MEL

AB-PO

AB-PO,TS-CV,AT-MEL

AB-PO,AB-CO,AT-MEL

AB-PO,AB-CO

AB-PO,AB-CO,AT-MEL,TS-CV

AB-PO,TS-EL

AB-PO

AB-PO,AB-CO

AB-PO

3 6 9 12 15 18 21 24 27 1 4 7 10 13 16 19 22 25 28 31 3 6 9 12 15 18 21 24 27 30 3 6 9 12 15 18 21 24February 2004 March 2004 April 2004 May 2004

10 weeks for a sector- 5 weeks for an UA- 3 weeks for a RR- 2 weeks for an arc

Sector 78


Circuit type tests (60A, 120A, etc…)

•First Powering tests (at minimum stable current)• Check the start of the power converter• Set up of current loop and verify the stability• Safety system

•Intermediate current• Verify the current loop stability• Safety system

• Nominal current

• Power converter performance in current source

Cold power tests Cold power tests (EDMS 519716)(EDMS 519716)


Main dipole circuits

•Main issues with the RB circuits• Starting of the power converter (> 20 s to go to the

minimum current)• Setting current loop (noise of the current measurement) • Discharge system in the odd point• Recuperation mode• Safety system• Power converter performance in current source

Cold power testsCold power tests


MQM circuits

•Main issues with the MQM circuits•Starting of the 2 power converters•Setting current loop and verify the performance

(resistive coupling) •Safety system

6 kA 6 kA



Inner Triplet main quadrupole circuits (EDMS 531773)

RST-

Iref1

Ipc1

RST-

Iref2

RST-

Iref3

Ipc3

Ipc2

Deco

uplin

g s

yst

em

4.7 kA±600 A

7 kA Ipc1

Ipc2Ipc3

Vref1

Vref2

Vref3

7 kA

7 kA



•Test strategy•Test the 5 kA circuit alone (inner power converter)•Test the 7 kA circuit alone (outer power converter)•Test the 5 kA + 7 kA with decoupling loop•Test the 5 kA + 7 kA + 0.6 kA with decoupling loop•Set up of the current loops

Inner Triplet main quadrupole circuits

4.7 kA±600 A

7 kA

7 kA

7 kA




7R 8L 8R 1L 1R 2L 2R 3L 3R 4L 4R 5L 5R 6L 6R 7L

Main Circuits (RB, QF and QD)

Low current loop setting 2 1 1 1 1 1 1 1Low current FW test 2 1 1 1 1 1 1 1Intermediate current FW 2 1 1 1 1 1 1 1Nominal current FW tests 2 1 1 1 1 1 1 1DCCT Calibration 6 3 3 3 3 3 3 3

Inner Triplet Quadrupoles System

Tests at low current 10 5 5 5 5 5 5 5Intermediate current discharge tests 2 1 1 1 1 1 1 1Nominal current discharge tests 2 1 1 1 1 1 1 1DCCT Calibration 2 1 1 1 1 1 1 1

Inner Triplet Correctors + D1

Low current loop setting 3 1.5 1.5 1.5 1.5 1.5 1.5 1.54, 6 and 8 kA converter

Low current loop setting 1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5600 A without Energy Extraction

Low current loop setting 1 1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5600 A with Energy Extraction

Low current loop setting 1 1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5120 A Orbit correctors

Current loop setting 1 1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.560 A Orbit correctors

Current loop setting 1 1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5Total de jours de 16H par point et secteur 4 38 19 12 12 19 19 2 2 9.5 9.5 12 12 9.5 9.5 2Total de jours de 16H par secteur

sector 7-8 sector 8-1 sector 2-3sector 1-2 sector 3-4 sector 4-5 sector 6-7sector 5-6

11.5 21.5 21.5 11.521 31 31 21

Other sector:7 days for the 3 main circuits8 days for the IT circuits4 days for the other circuits

First sector:14 days for the 3 main circuits16 days for the IT circuits8 days for the other circuits


ConclusionsConclusions

1. The power converters are tested before their installation but theses tests are limited

not real load not real environment not with the other systems (PIC and WorldFIP)

2. The DC cables are not tested before their installation not tests in power

3. The main circuits (RB and RQ) and Inner Triplet request a special attention

Power Converters, water cooled cables and warm bus bars

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