Consolidation program SPS Main Power Converters (Dipole & Quadrupole )

1. Consolidation program SPS Main Power Converters (Dipole & Quadrupole) K. Kahle / Q. King / G. Le Godec (TE-EPC) IEFC Workshop, 9 March 2012

2. Outlines • SPS consolidation overview • Transformers • Thyristor bridges • Electronics and CIS • Powering tests • Conclusions

3. Overview • Consolidation overview 3

4. Overview SPS Dipole Circuit • Power system ratings: 25 kV/6kA/150 MW • 12 converters connected in series • 2 active spares. • Spares

5. Overview SPS Quadrupole Circuit • Power system ratings: 4.8 kV/2.2 kA/ 10.6 MW • 2 converters + 1 active spare • 2 converters • 1 active spare

6. Overview • 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: Filtercapacitors replacement (PCB elimination), • 2002: New Earth Protection and Discharge System (Crowbar), • The consolidation program shall continue to maintain the excellent availability of the machine 6

7. Overview SPS powering consolidation: A large project! • 18kV cables • Qty  20 km • LS1 • EN/EL • Transformers • Qty = 68 • LS1 • TE/EPC • Thyristors • Qty = 68 • LS1 • TE/EPC • Electronics and CIS • LS1-2 • TE/EPC

8. 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).

9. Transformers • Transformers • For SMD and SMQ 9

10. Transformers • Oil Transformers … reasons to change • Ageing (≈30 years of operation): • High maintenance costs and urgent need of consolidation: • Corrosion, • 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). 10

11. Transformers Existing oil transformers 11

12. Transformers Transformers… 4 pre-series transformers already in operation in 2011, 4 additional transformers installed for the operation in 2012, 12

13. Transformers 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. 13

14. Transformers Preparations in 2012… • Access road around BA2 to be rebuild (budget 55 kCHF covered by GS), 14

15. Transformers 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. 15

16. Thyristors • Thyristor bridges • For SMD and SMQ 16

17. Thyristors • 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). 17

18. Thyristors Thyristors: existing water-cooled power bridges 18

19. Thyristors Thyristors… Integration into the existing racks

20. Thyristors Thyristors… Two parallel bridges Replaced by one single bridge 20

21. Thyristors 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. 21

22. Thyristors 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 22

23. Electronics and CIS • Electronics and CIS 23

24. Electronics • 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. 24

25. Electronics • Electronics… Electronics designed by S. Van Der Meer 25

26. Electronics • First step: integration of Current Regulation in the Mugef in LS1. MUGEF in 2012 I ref Vref Analogue Voltage Regulation Function Generation Analogue Current Regulation Power part DAC Vmeas Imeas Vref MUGEF after LS1 I ref Analogue Voltage Regulation Func. Gen. Digital Current Regulation Analogue Current Regulation Power part DAC Vmeas Imeas ADC Analogue regulation can be reactivated in minutes 26

27. Electronics • 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. 27

28. CIS Command and Interlock System (CIS) Modernization of the CIS system First phase Reprogramming of new PVSS for CIS was not yet successful. We had to return to the old HP workstation HMI (BA3) Second phase Master PLC (BA3) Local PLC’s (all BA’s) Local PLC’s (all BA’s) Local PLC’s (all BA’s) … 28

29. Powering tests • Powering tests 29

30. Powering tests 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, 30

31. Conclusions • Conclusions 31

32. Conclusions • 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, 32

33. Thank you… 33