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E951 POWER SUPPLY SAFETY REVIEW 9/06/02 IOANNIS MARNERIS Brookhaven National Labs. Project Goals • The project goal is to pulse a magnet with 15 cm diameter bore, capable of a peak field near 15 T and a repetition rate of about 30 minutes. • Provisions are made to pulse first to 5 T, then 10 T and then 15 T. • To do this we will use 4 existing SCR type dc power supplies from the experimental area in series-parallel connection. • Each power supply is rated at 3600 Adc, +/- 150 V Parameters of the Pulse Magnet System with 1 sec flat top Units Outer radius (cm) Copper mass (kg) Voltage (V) Peak current (A) Field (T) Inductance (mH) Initial temperature (K) Time t1, to end of flat tap (s) Pulse length, tp (s) Initial Resistance (mOhms) Resistance at t1, (mOhms) Resistance at tp, (mOhms) Dissipation at tp, (MJ) Case 1 30.0 1943 150 3600 5.0 138 84 8.2 11.1 30.2 34.1 34.1 2.70 Case 2 30.0 1943 300 7200 10.0 138 74 7.3 10.1 23.5 35.3 37.2 9.1 Case 3 40.0 3644 300 7200 14.5 436 30 16.3 24.1 11.0 33.0 38.2 15.2 Performance of the 5T magnet with case 1 power supply 84 K Magnet Pulsed at 150 V to 3.6 kA, 5 T with 1-sec. Flat Top 40 200 36 160 Voltage 120 28 80 24 40 20 0 16 -40 12 -80 8 -120 4 0 -160 Current 0 2 4 6 Time from start of pulse [s] 8 10 -200 Power-supply voltage [V] Current [kA] and Resistance [m] Resistance 32 Performance of the 10T magnet with case 2,3 power supply 74 K Magnet Pulsed at 300 V to 7.2 kA, 10 T with 1-sec. Flat Top 40 500 36 400 Resistance 32 300 28 200 24 100 20 0 16 -100 12 -200 8 -300 Current 4 0 -400 0 2 4 6 Time from start of pulse [s] 8 -500 10 Power-supply voltage [V] Current [kA] and Resistance [m] Voltage Performance of the 15T magnet with case 2,3 power supply 30 K Magnet Pulsed at 300 V to 7.2 kA, 14.5 T with 1-sec. Flat Top 40 500 36 400 Voltage 300 28 200 24 100 Resistance 20 0 16 -100 12 -200 8 -300 Current 4 0 -400 0 4 8 12 16 Time from start of pulse [s] 20 -500 24 Power-supply voltage [V] Current [kA] and Resistance [m] 32 Case 1 power supply • 540 KVA power supply rated at 3600 A, +/-150 V • Thyristor-control six-pulse rectifier, available at Brookhaven Labs from previous experiments. (Model Meeker #431) • The power supply is presently configured as DC power supply • We need a new regulator to be able to pulse it, based on the existing design for the AGS Main magnet power supply. • The controls and interlocks of the power supply must be updated. • New direct current potential transformer (DCPT). • New crowbar circuit to absorb magnet stored energy. • Similar upgrades have been made during the Booster project with great success. Case 1 power supply regulator CURRENT REF. 1V=750A + VOLTAGE REF. 1V=20 V + - + - + MAGNET CURRENT FC MOD. 1 3600 A, 150 V - PT L=0.138 Henries Rm ax=0.038 Ohm s DCCT Case 2,3 power supply • Four series-parallel, 540 KVA power supplies rated at 3600 A, +/-150 V each, Total rating 7200A, +/-300V. • Thyristor-control six-pulse rectifiers, available at Brookhaven Labs from previous experiments. (Model Meeker #431, in parallel with # 433, and #429, in parallel with # 432, ) • The power supplies are presently configured as DC power supplies. • We need a new regulator to be able to pulse it,based on the existing design for the AGS Main magnet power supply. • The controls and interlocks of the power supply must be updated. • New direct current potential transformer (DCPT). • New direct current current transformer (DCCT). • New crowbar circuit to absorb magnet stored energy. • Similar upgrades have been made during the Booster project with great success. Case 2,3 power supply regulator 1V=20V - FC MOD. 3 3600 A, 150 V P T MOD. 1 3600 A, 150 V FC + 1V=20V + + MOD. 2 3600 A, 150 V + + + - + - FC DCCT VOLTAGE REF.1V=40V + L=0.45 Henries P T CURRENT REF. 1V=750A - MAGNET CURRENT FC + Rmax=0.038 Ohms MOD. 4 3600 A, 150 V More power supply details • The 3-phase, 480-V input power to each supply will be fed from new, lockable disconnect switches. • Each switch will be fed from an existing AC circuit breakers in an existing substation. • Two parallel power supplies (MOD 1 and MOD 2) will be fed from the same existing substation and the other two (MOD 3 and MOD 4) from a different existing substation. • The power supply will be fully programmable from 0 to 7200A. It will have two voltage regulators as the inner loops and a current regulator as the outer loop. • The anticipated overall bus resistance should not exceed 1 m. 1 1/4 water cooled buss will be used we already have. • All the old interlocks will be updated using an Allen Bradley Programmable Logic Controller (PLC). • Minimum repetition rate for case1 magnet is 5 minutes, for case 2 magnet is 20 minutes, for case 3 magnet 30 minutes. AC one line diagrams Controls rack layout PROGRAMMABLE LOGIC CONTROLER SLC 504 AND I/O MODULES BY ALLEN BRADLEY READY PANEL TERMINAL 600 TO MONITOR INTERLOCKS BY ALEN BRADLEY BNC SIGNALS OFF STBY ON LOCAL CONTROLS 2 VOLTAGE REGULATORS (1 BOARD) 1 CURRENT REGULATOR BOARD 1 DRIVER/LINEARIZATION BOARD 1 BUFFER BOARD 1 POWER SUPPLY BOARD PSI, VREF. MOD1,2 VREF. MOD3,4 PSI, IREF. CPU V108 V102 T I M I N G WFG VREF. M OD 1,2, 3,4 WFG IREF. Power supply interlocks • • • • • • • • • • • • • • DC overcurrent RMS magnet current interlock AC overcurrent Blower failure Ground Fault Magnet faults Magnet resistance interlock. Cryo interlocks Doors are open SCR overtemperature SCR failure Power supply cubicle overtemperature Soft start overload Bus water flow and overtemperature Power supply layout Power supplies picture 1 Power supplies picture 2 Power supplies picture 3 Power supplies picture 4