Pulse cables for XFELxfel.desy.de/localfsExplorer_read?currentPath=/afs/... · Pulse cables for...
Transcript of Pulse cables for XFELxfel.desy.de/localfsExplorer_read?currentPath=/afs/... · Pulse cables for...
![Page 1: Pulse cables for XFELxfel.desy.de/localfsExplorer_read?currentPath=/afs/... · Pulse cables for XFEL 14.07.04. Pulse cable for XFEL Hans-Jörg Eckoldt Why Pulse cable? • Basic idea](https://reader034.fdocuments.in/reader034/viewer/2022052310/5f0f8a187e708231d444aa6a/html5/thumbnails/1.jpg)
Pulse cable for XFEL
Hans-Jörg Eckoldt
Pulse cables for XFEL
14.07.04
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Why Pulse cable?
• Basic idea came from the TESLA LC
– About 600 modulators have to be installed
– This large number of units should NOT be installed into the
tunnel.
• Reliability
• Maintainability
• Space would have been to small for the 800 GeV upgrade
• The modulators shall be installed in service halls at ground level
• The pulse transformer have to be installed inside the tunnel
• The energy has to be transported into the tunnel via these cables
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Overview TESLA
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Pulse cable for XFEL
Hans-Jörg Eckoldt
View of TESLA tunnel
Pulse cables
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Tunnel Design
50 cm
520 c
m
190 c
m
440 cm
80 cm
90 c
m
30 cm
125 c
m
210 cm
Figure 2. Main LINAC, Damping Ring & Electronic Station Pulse cables
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Pulse cable for XFEL
Hans-Jörg Eckoldt
View of the XFEL Tunnel
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Pulse cable for XFEL
Hans-Jörg Eckoldt
XFEL
• Technical data of the modulator for TESLA
• max. klystron gun voltage: 120 kV
• max. klystron gun current: 140 A
• Primary Voltage 10 kV
• Primary Current 1680 A
• high voltage pulse length: 1.7 ms
• pulse repetition frequency: 10 Hz
• max. pulse power: 16,8 MW
• average power: app. 300 kW
• Number of Modulators in TESLA: 38
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Requirements
• No significant delay for the pulses
• No distortion of the waveform
• No “electro smog” ejected into the tunnel
• Low losses
• Radiation hardness
• Good fire resistance due to the large amount of burning material
• Very high reliability
• Good price
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Questions to be solved
• How to the terminations and splices look like?
• How to transport the cables?
• How to install the cables?
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Construction drawing
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Photo of pulse cable
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Termination
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Terminations
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Pulse cable for XFEL
Hans-Jörg Eckoldt
General comments
• The cable is called a pulse cable due to the fact that the
modulator produces pulses
• However when looking at the time of 1,7 ms and the rise
times of more than 100 µs for the current, the cable is
working in the DC region.
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Pulse cable for XFEL
Hans-Jörg Eckoldt
No significant delay for the pulses
• this would decrease efficiency
• Simulation showed that a decrease in Z0 lead to a better
pulse behavior. Too achieve this two possibilities exist. :
– Increase the diameter of the inner conductor
• The construction is not easy
• Splices in the tunnel since only short pieces can be manufactured
– Put cable in parallel
• Good solution since standard manufacturing process
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Low losses
• The losses are mainly determined by the resistive part of the copper
• There is no significant damping of the semiconductor layers as seen in high frequency/short pulse applications
– Semi conducting layers can be used
– Again standard manufacturing for high voltage cables can be used
• Skin effects have to be taken into account
– By paralleling the effect of the skin effect reduced since
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Pulse cable for XFEL
Hans-Jörg Eckoldt
No reflections on the cables
• The pulse traveling along the cables will see the pulse
transformer at one end.
• With the stray inductance the cable is not adapted and
the pulse would be reflected.
• Therefore an adaptation network consisting of resistor
and a capacitor has to be introduced for a broad band
adaptation .
• For the four cables a value of 6.6 Ohm and 2.5µF give
good results
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Pulse cable for XFEL
Hans-Jörg Eckoldt
RC-Adaptation-Network
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Pulse cable for XFEL
Hans-Jörg Eckoldt
No “electro smog” into the tunnel
• For the cable a triaxial design was chosen. The fields will
stay within the cable between the inner and middle layer
• Additionally an outer shield consisting of a enclosing foil
was introduced
• Measurements for EMC are still to be performed
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Radiation hardness
• By the choice of the material there are no problems to be
expected.
• XLPE (cross linked Poly ethylene) has a radiation
hardness of 5 * 107 rad
• Additionally the cables will be beneath concrete
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Good fire resistance
• Due to the large number of cables and the amount of XLPE a large fire load is introduced into the tunnel
• To counteract to this the construction was carefully chosen. The cable is specified according to IEC 60332 Cat. A
– The outer shield is built as a closed foil building a barrier for the fire and the burning material
– Two layers of FRNC (Flame retardant non corrosive) materials are introduced.
• This was proven by a fire propagation test
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Help on construction, calculation
• M. Filtz, Institut für theoretische Elektrotechnik, TU Berlin
• Dr. Pfeiffer, Draka Multimedia Cable
• Dr. Fricke, Siemens
• W. Buchwald, Kaiser Kabel, später Nexans
• Ansoft, Supply of modells for cable simulation
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Pulse cable for XFEL
Hans-Jörg Eckoldt
With these requirements the cable was
ordered
• The cable was purchased in a European wide bid for a
tender
• Several companies who are able to manufacture the
cable. The cable can be produced with standard
production procedures.
• The order was given to HVT, Germany
• Dielectric Sciences, US
• Essex, UK
• SAGEM, France
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Let’s come to the existing cable
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Tests with the cable in factory
• Routine tests as for any other high voltage cable
• Type test for fire propagation test IEC category A
• Smoke density test
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Preparation for fire propagation test
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Cable being firedduration 40 min
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Cable after fire propagation test
self extinguished after 20 min
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Cable after fire propagation test
Allowed propagation: 2.5 m
Reached propagation: 0.8 m
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Cable after smoke density test
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Destruction during smoke density test
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Transport of the cable
drum with 3000 m
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Installed pulse cable
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Pulse cable for XFEL
Hans-Jörg Eckoldt
“tricky” parts of installation
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Electrical Test
• First tests with modulator at low voltage (max. 5kV)
• The commissioning of the test was extremely successful
• Tests on test load to check the short circuit behaviour
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Simulation model for modulator, cable and
klystron incl. arcs
+
V
�������
D1
D2
L1 330u
R1 160C1 80u
C_Bounc700
2m
C := 1.4m
V0 := 8k
CTRL := S1
TH1
CTRL := zuenden
TFR1P2W1
VM1
LTRA1
C := 1n
R := 119u
LEN := 1.5k
G := 0
L := 50n
t_1>0.1
Dklys1 Rkurz 100m
U_brenn
100
DkS2
CT RL := S
S3
CT RL := S
+
VVM4
A
AM3
LM := 0.8
LS1 := 0.194m
LS2 := 0.1uRa 6.6
Ca 2.5u
+
V
VM2
N0040
N0015
Kl ystron
KLYSTRON17
A
AM1
A
AM2
R2
L2
40u
#
XY
Varistor
CH := XYVaris tor.VAL
XYVaristor
F ILE := resistor_ssh__XY Varistor.mdx
100m
D3R3
200m
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Current in modulator and transformer
A M1.I [A ] A M2.I [A ]
t [s ]
1.2k
-0.2k
0
0.2k
0.4k
0.6k
0.8k
1k
0 3.5m0.5m 1m 1.5m 2m 2.5m 3m
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Simulated klystron voltage at low voltage
VM4.V [V] KLYSTRON17.KLYSTR_
t [s ]
0.1Meg
-10k
0
20k
40k
60k
80k
0 3.5m0.5m 1m 1.5m 2m 2.5m 3m
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Measurement
U Klystron
I Klystron
I Modulator
U Modulator
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Test load
• Resistive value of 8.9 Ohms
• Inductance of 200 µF
• Ignitron to produce a short circuit at any
moment during the pulse
• Crowbar test with a wire to prove the allowed
amount of Joule deposited
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Test lead for 10 kV, Crowbar test
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Tests with test load
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Tests with Test load Short circuit
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Goal reached 128 kV
14.07.04 11.45
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Pulse cable for XFEL
Hans-Jörg Eckoldt
Next Tests
• Test with klystron to full voltage
• Test with full pulse length
• High power test with 10 Hz, 128 kV, 5 MW Klystron
• Measurement of the electro magnetic radiation
• Long term tests with modulator
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Pulse cable for XFEL
Hans-Jörg Eckoldt
The pulse cables behave in the way it is
foreseen.
The functionality is now proven for XFEL