BurnetPractice PDF

CERN Accelerator School
Putting it into Practice

2
Jean-Paul Burnet
CERN
CAS, Baden, 7-14 May 2014
Introduction
In this talk,
I will try to answer to questions raised in power converter requirements
I will try to propose a list of solutions,
of tricks,
of recommendations,
of warnings.

3
B-field uncertainty / accelerator operation
Circuit layout
Energy saving
Capacitor ageing
EMC / grounding
IGBT ageing
Control performance

4

In most of the synchrotrons, all the magnets (quadrupole, sextupole, orbit correctors,)
are current control and the beam energy is controlled by the dipole magnet current.

To mitigate the B-Field uncertainty, the solutions are :
- Use the degauss or pre-cycle technique
- Get a high-precision magnetic field model (10
-4
)
- beam steering application for orbit and trajectory correction
- Real time orbit feedback system
- Real time tune feedback
- Real time chromaticity feedback
Or / and
- Real-time magnetic field measurement and control (10
-4
)
needs an extra magnet outside the machine with instrumentation in its gap.

5
Solution for B-field uncertainty
To solve this problem of hysteris, the classical degauss technique is used.
For a machine working always at the same beam energy, few cycles at beam energy will
degauss the magnets. Example LHC precycle.
For machine or transfer line with different beam energies, the degauss has to take place
at each cycle. Solution, always go at full saturation in each cycle.
6
Solution degauss technique
beam
Period n-1 Period n+1 Period n
26GeV
beam
time
beam
20GeV
14GeV
A
C
A
B
C
D
E
F
G
B
D
E F
G
Edt
NI
D
Without reset With reset
I
magnet
t
B
E
A
M

e
j
e
c
t
i
o
n
Reset point D where
magnetic saturation
occurs and magnetic flux
may not increase any
further
Minor B-H loop
achieved by
reset cycle
B
E
A
M

e
j
e
c
t
i
o
n
B
E
A
M

e
j
e
c
t
i
o
n
Reference magnet with B-field measurement.

7
Solution B-field control
The LHC has a magnetic model.
Accelerator physicists use the FiDeL tool to generate the current reference.
The aim is to provide the integral transfer function (integral field vs. current) in a form suitable for inversion (current vs. integral
field) for each circuit in the LHC. In addition, for the main ring magnets FiDeL will provides a prediction of the field errors to be
used to set the corrector circuits.

8
Solution: Magnetic Model
https://lhc-div-mms.web.cern.ch/lhc-div-mms/tests/MAG/Fidel/

4
th
December 2008
9
First LHC Beam 2 around the ring
1. Beam to TDI
2. Beam to IR7
3. Beam to IR6
4. Beam to CMS
5. Beam to IR3
Steve Myers report
beam steering application for orbit and trajectory correction
= operator tool
https://jwenning.web.cern.ch/jwenning/do
cuments/YASP/YASP-user-guide.pdf

Solution: beam steering
4
th
December 2008
10
First LHC Beam2 around the ring
1. Beam to TDI
2. Beam to IR7
3. Beam to IR6
4. Beam to CMS
5. Beam to IR3
6. Beam to ALICE
Steve Myers report
4
th
December 2008
11
First LHC Beam2 around the ring
1. Beam to TDI
2. Beam to IR7
3. Beam to IR6
4. Beam to CMS
5. Beam to IR3
6. Beam to ALICE
7. Beam to ATLAS
8. Beam to LHCb First Turn !
Steve Myers report
The LHC has an orbit feedback system.
It needs BPM (Beam Position Monitors). The feedback controller acts on the orbit
corrector magnets

12
Solution orbit feedback
http://cds.cern.ch/record/1054849/files/thesis-2007-058.pdf?version=1
Dynamic compensation
https://jwenning.web.cern.ch/jwenning/documents/Orbit/FB/Snapb-
EPAC02.pdf

When the circuits are split:

- The tracking error shall be limited (control performance)
- The magnet hysteresis shall be reset (pre-cycle)

Recommendation:
Place the same controller in front of all the power converters.

Example:
LHC tracking error between
the 8 sectors

13
Solution for individual powering
Solution for nested circuits
14
Nested powering scheme can be a nightmare for power engineers !!

Very complex control, it is like a car with many drivers having a steering wheel
acting on only one wheel.

RQTX2 5kA 8V
RQX 7kA 8V
RQTX1 600A 10V
FWT 7 kA
HCRYYAA
FERMILAB
MQXB
Ultimate current : 12290 A
Inductance : 18.5 mH
Stored Energy at nomimal
current : 1200 kJ
KEK
MQXA
Stored Energy at nominal
current : 1890 kJ
KEK
MQXA
Stored Energy at nominal
current : 1890 kJ
Free Wheel
Diode
Reduce capital cost but decrease availability!
15
Very difficult to operate and repair, long MTTR.

All converters have to talk each others.

Need a decoupling matrix to avoid fight between converters
!

FUNCTION
GENERATOR
CONTROLER
+15V
+5V
-15V
FUNCTION
GENERATOR
CONTROLER
+15V
+5V
-15V
FUNCTION
GENERATOR
CONTROLER
DCC
T
600
A
DCC
T
600
A
+15V
-15V
INNER
TRIPLET
DIAGNOSTIC 8KA
S
K
C
M
D
F
G
C
8
K
A
S
K
C
M
D
F
G
C
6
K
A
DIAGNOSTIC 6KA
SK CMD 6KA
SK CMD 8KA
INTERLOCK IN 8KA
INTERLOCK OUT 8KA
INTERLOCK IN 6KA
INTERLOCK OUT 6KA
+ - + -
IN
T
L
K
F
W
T
C
M
D
F
W
T
D
IA
G
F
W
T
LEM FWT
SK FLOW
DCCT A 600A
DCCT B 600A
SKINTK 600A
DIAG 600A
CMD 600A
D
C
C
T
H
E
A
D
A
8
K
A
D
C
C
T
H
E
A
D
B
8
K
A
D
C
C
T
H
E
A
D
A
6
K
A
D
C
C
T
H
E
A
D
B
6
K
A
D
C
C
T
8
K
A
D
C
C
T
6
K
A
DCCT STATUS A 8KA
DCCT STATUS B 8KA
DCCT STATUS A 6KA
DCCT STATUS B 6KA
CHASSIS Type 4
HCRFEEA
CHASSIS Type 11
HCRFEMA
CHASSIS FWT
HCRYYAA
Elleta
https://edms.cern.ch/file/1100412//LHC-Inner-Triplet-I_PAC_2010.pdf

16
Look at the current and voltage of RQX while RTQX2 current is changing!

Nested circuits arent RECOMMANDED !
LHC inner triplet works perfectly well but MTTR is much higher.
RHIC had many difficulties with nested circuits.

Solution for HL-LHC
17
For the LHC upgrade project (High-Lumi LHC), the inner triplet magnet will be
replaced by new ones with a larger aperture.

The solution proposed is to have one power converter for Q2a-b magnets and one
for Q1 Q3 magnets!
It still requires trim power converters to have the full flexibility with beam optics.

Simpler powering scheme!

Solution for large dipole circuit
The SPS have 744 dipole magnets. The total voltage applied is 24kV for 6kA.

12 power converters are placed between series of magnets. Each power converter is
rated at 2kV. The maximum voltage to ground of the magnet is then 2kV.

Large reduction of insulation constraint on the magnets!
18
SMD5 SMD8 SMD7 SMD14 SMD12
SMD11
SMD10
SMD9 SMD4 SMD3 SMD13 SMD2
SMD1
SMD6
-
1
k
V
+
1
k
V
BA5 BA6 BA1 BA2 BA2
BA2 BA2 BA3 BA4 BA5
BA3
BA4
BA6
BA1
2kV 2kV
Solution for magnet grounding
With a resistor, an earth fault cant be detected close to the polarity connected to
earth.
Solution: active detection
19
Earthing Circuit: Passive Detection

Advantages
Simple

Drawbacks
Fuse status unknown
Dead zones for low voltage drops

Earthing Circuit: Active Detection

Advantages
Earth fault detection before energisation
Fuse status known
No dead zone for low voltage drops and 1-
quadrant converters

Drawbacks
Dead zones for high voltage drops since
common mode voltage must be kept limited
to few volts (safety reasons)
Earthing Circuit: Active / Passive
Detection (dynamic selection)

Advantages
Earth fault detection before energisation
Useful for high voltage drops when
passive detection is preferable

Drawbacks
Dead zones for low voltage drops
Earth fault: |V
1
|>0.5V
|I
earth
|>50mA
R
cables
200m
R1 10
R3 100
Fuse 1A
R2 10k
I
Source
100mA
R
cables
2m
Dead zones: |V
AB
| < 0.5V
Earthing System
DETECTION
Converter Output Common
Mode Voltage
0V
passive
active
Converter STATE
off
on
Converter Ouptut Voltage
0V
0A
Converter Ouptut Current
Dynamic selection through CMD signal:
Active detection = converter OFF state
Passive detection = converter ON state Earth Fault in B point
-INominal
+500A -500A
+INominal
+5A -5A
-INominal +INominal
R
cables
200m
R
cables
2m
Earth Fault in B point
-INominal +INominal
-45A
-INominal +INominal
-155A
R1 10
Fuse 1A
R2 10k
R1
R2
V1
Fuse
A B
Earth
Fault
VAB
Earthing
Circuit
Rcable
Earth fault: |V
1
|>0.5V
|I
earth
|>50mA
Earth fault: |V
1
|>0.5V
|I
earth
|>50mA
R1 10
R3 100
Fuse 1A
R2 10k
I
Source
100mA
R1
R2
Fuse
R3
A
V1
Isource
0VVCC
Up to Vcc*
*Internal to the Converter
B
Earth
Fault
Earthing
Circuit
Rcable
VAB
R1
R2
Fuse
Isource
Over-voltage protected
R3
CMD
0VVCC
Up to Vcc*
*Internal to the Converter
A
V1
Earthing
Circuit
https://edms.cern.ch/file/997662//PAC2009_Earth-Current-Monitoring-Circuit-for-Inductive-Loads.pdf

Linacs and transfer lines
LINAC4 : Beam is passing through in one shot, with a given time period;

Most of the magnets and all klystrons are pulsed.

t (s)
B (T),
I (A)
Beam passage
Solution for energy saving
20
800s
500ms
Beam duty cycle : 0.016%
21
New topologies for discharged converters.

- Fast ramp-up (IGBT polarity switches)
- Flat top control (active filter or IGBT in
linear mode)

Energy saved compared to DC powering = 99.4%

Solution for energy saving
0.00 2.00 4.00 6.00 8.00 10.00
0.00
100.00
200.00
300.00
Curve Info
L1.I
TR
http://te-epc-lpc.web.cern.ch/te-epc-lpc/converters/mididiscap/general.stm

22
New concept for energy management
From 1.4Gev to 2GeV

Magnet saturation effect

Same ramp-up time

Increase ramp-up time to keep the same
RMS current in the magnets
B-field: x1.3

Peak Current: x1.5

Power: x1.8

Peak Power: x2
New challenging Main Power Supply
Project of beam energy increase at the Booster

Present power converter:
4 thyristor bridges in series, 4kA/4kV
With SVC
All magnet coils in series.

23
2 power converters + 1 full spare
IGBT converters with capacitive storage 3 * 2.6MJ
Peak power 2 * 14MW
Rms power 2 * 1.5MW

quadrupole
24
Present power system:
- Peak power applied to magnets: 14MW
- Peak power taken on the grid: 14MW + SVC 17MVar

New power system
- Peak power applied to magnets: 28MW
- Peak power taken on the grid: 5MW + no SVC
- No increase of magnet losses! Same average power !

25
Capacitor ageing of POPS
A capacitor unit is 2mF.
68 basic elements (cans) are connected in parallel
Polypropylene dielectric
Aluminium metalisation
9um thick
+
Floating
electrode
-
Several hundreds meters of double
film are rolled-up.
The double film layer constitutes a
series connection of 2 capacitors.
26
Capacitor ageing
Huge metallization
evaporation
Flash Over on surface
between + and -
Flash Over on surface
between Floating electrode
and a polarity
1. Electric stress on surface: 4mm for
5kV looks really tight (probably under
dimensioned)
2. Electric stress in the dielectric:
E=250V/um is generally considered a
limiting value for real applications in pp.
27
Capacitor ageing
The first hypothesis is unexpected ageing caused by low frequency charge-discharge
cycling.

film corrosion is due to partial discharged which demands on dv/dt.

Capacitor manufacturers are under economical pressure, which leads to design without
any margin.

Put this margin in your specification.
For example, specify 6kV capacitors for operation at 5kV.
Floatings
Converters
Chargers
Converters
28
Capacitor ageing
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0
2000
4000
6000
8000
20% unbalance in one phase

UdutR
UdutS
UdutT
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0
1000
2000
3000
4000
5000
6000
time [s]

Udc
D
CS
Idc
D
CS
CERN is building a test stand for accelerated testing of different capacitor technologies
with a combination of DC+AC voltage.
29
Sensitivity to grid perturbations
CERN is affected by grid perturbations.
The most sensible circuits are the warn magnets in LHC.
Trigger beam dump
30
Sensitivity to grid perturbations
Classical topology but with special design to ovoid trip due to grid perturbations.
AC
DC
DC
DC
Intermediary
DC-link
Extended
Delta
Transformer
AC
DC
DC
DC
Intermediary
DC-link
Extended
Delta
Transformer
Series or parallel
connection with
interleaving
Interleaving on
AC side
Input
stage
Output
stage
EMC: Common mode voltage
31
At the start of POPS, all the performance were verified in differential mode.
Everything was fine, but with the beam, the tune was disturbed.

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 AC
Scc=600MVA
OF1 OF2
RF1 RF2
TW2
Crwb2
TW1
Lw1
Crwb1
Lw2
MAGNETS
AC/DC converter - AFE
DC/DC converter - charger module
DC/DC converter - flying module
2 2.5 3 3.5 4
-8000
-6000
-4000
-2000
0
2000
4000
6000
8000

(PAM1 + PAM2) [v]old
(PAM1 + PAM2) [v]new
2.85 2.9 2.95 3 3.05 3.1
1760
1780
1800
1820
1840
1860
1880
1900
1920
1940
1960

(PAM1 + PAM2) [v]old
(PAM1 + PAM2) [v]new
Differential voltage applied to magnet
20Vpp as specified
32
Then, we looked at the common mode voltage (Between one polarity to ground).

1.5 2 2.5 3 3.5 4 4.5
-2500
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
1500Vpp!
Output filter
Earth resistor
Cables
33
Solution: Place EMC capacitor to earth via busbar
Use metal plate, no wire or cable

100Vpp
Output filter
Earth resistor
Busbar to kill all stray inductances
EMC capacitor
Stray inductances
CM filter capacitor
Vearth
34
Example of DC filtering with EMC capacitor

SCB Filter
SCA Filter
SCB Inductor
SCA Inductor
EMI Caps EMI Caps
Grounding
Particles accelerators are very sensitive to EMC (conducted and radiated noise).

Need a meshed earth !

35
http://indico.cern.ch/getFile.py/access?contribId=44&se
ssionId=9&resId=0&materialId=slides&confId=85851
Grounding
Appling good EMC rules to power converters:

Use metal plate to interconnect and not cable.

Yellow-green cable only for
Personnel safety
Not for EMC
36
Solution for IGBT cycling
The life time of the IGBT is limited in number of thermal cycles.

IGBT manufacturers provide expected number of cycles depending of Tj

Solutions:
- reduce IGBT stress by interleaving technique (more cells in parallel)
- Oversize IGBT to decrease the Tj:
POPS example: 15 millions cycle / year TJ<25C with press pack IGBT

37
Minimum duty cycle
38
The IGBT has a minimum pulse width and each IGBT leg needs dead time.
This creates non linearity in the PWM control at low voltage.

Minimum duty cycle
39
Thyristor have also a minimum turn ON time.
The discontinuity of the current in the choke is also limiting the minimum current of the
converter.

To facilitate the control of the accelerator, an identical controller shall be placed in
front of all the power converters.

Example of SESAME with PSI controller

40
Solution for accelerator control
I
measured

Iref
Need digital electronics to achieve high performance control
V
I
B
Vref
e
V

G(s)
e
I

+
Reg.
F(s)
-
DAC
Power converter control
41
Need two DCCTs
to be sure of the
measurement!!
Current measurement
42
Do you need to calibrate your measurement chain?

What?
When?
How?

Ask the specialists!

Do you need a standard lab?

Burden resistor
Reference voltage
Reference current source
Reference DCCT

LHC class 1 global accuracy
43
0
1
2
3
4
5
F
r
e
q
u
e
n
c
y

ppm/year
Main dipole
converters offset
yearly drift
0
1
2
3
4
5
-8 -7 -6 -5 -4 -3 -2 -1 0 1 2 More
F
r
e
q
u
e
n
c
y

ppm/year
Main dipole
converters gain
yearly drift
Converter category Accuracy Class 1 year stability
Main Dipoles Class 1 50
LHC specification
50ppm/year

LHC result
< 10ppm/year with annual calibration

Possible improvement
< 2ppm/year with monthly calibration
Current regulation
44
The performance of the current regulation is critical for a machine.

RST controller provides very powerful features.
Dead-beat control is a must for operation!
Anti-windup is needed to control the saturation of the loop.

Summary

The magnet power converters are driving the beam.

Their performance are very challenging for particles accelerators.

Particles accelerators need all your
creativity in many technical fields!

Experience sharing helps us to make it right !

Many thanks to all speakers!!
45
CAS organisation
Many thanks to

Roger Bailey
&
Barbara Strasser

Many thanks to

Linny Rivkin
&
Ren Knzi

Many thanks to all sponsors !!!
46
Next step
POCPA: Power Converters for Particles
accelerators

This workshop is organized for power
supply specialists from all labs every
two years.

50 people participated to the Last
event in DESY.

Join us!

47
https://indico.bnl.gov/conferenceDisplay.py?confId=687

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CERN Accelerator School

Putting it into Practice

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