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