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Review of the experienceof LHC powering:

short-circuit tests and sector 7-8and start of powering sector 4-5

Frédérick Bordry

Review of the experienceof LHC powering:

short-circuit tests and sector 7-8and start of powering sector 4-5

Frédérick Bordry

1. Short-circuit test review2. Sector 7-8: what was done? Some highlights

3. Sector 7-8: what was not done? 4. What can we do faster when powering for the next sectors ?5. What can we not do faster when powering for the next sectors ?

1. Short-circuit test review2. Sector 7-8: what was done? Some highlights

3. Sector 7-8: what was not done? 4. What can we do faster when powering for the next sectors ?5. What can we not do faster when powering for the next sectors ?

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Short-circuit tests are not only power converter tests: energy extraction tests, DC cables tests, AC network conditions, cooling and

ventilation, interlocks, control,…

Short-circuit tests (SCT)

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Short-circuit tests

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Circuit Type

Sector

LHC1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-1

13 kA 3 3 3 3 3 3 3 3 24

Independently Powered Dipoles 3 2 2 3 1 0 2 3 16

Independently Powered Quadrupoles 14 7 6 13 12 5 7 14 78

600A with Energy Extraction 23 27 28 24 23 27 27 23 202

600A Energy Extraction in Converter 14 20 20 14 14 20 20 14 136

600A no Energy Extraction 16 9 2 9 9 2 9 16 72

80-120A Correctors 50 37 22 33 33 22 37 50 284

TOTAL 123 105 83 99 95 79 105 123 812

Circuit TypeSector

LHC1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-1

60A Closed Orbit Correctors 94 94 94 94 94 94 94 94 752Short-circuit tests

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UA47

UA43

RR53

USC55RR57

UA63

UA67

Point 7

RR73

RR77

UJ76

UA83

UA87

RR13UJ14RR17

UA23

UA27

ALICE

UJ32 UJ33

CMS

Point 6

LHCb

ATLAS

SPS

Point 4Point 3.3

Point 3.2

From October 2005 to

September 2007

Short-circuit tests

All tests were successfully concluded by a 24h endurance test (16h at ultimate and 8h nominal)

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General Services: AC Distribution (P,Q, THD)

WorldFip fielbus/ WiFI

Cooling for Power Converters, Power Cables and Energy Extraction

Ventilation (air temperature variation)

UPS System

Equipment directly linked to the SC circuits:

Power Converters

13kA and 600 A EE Systems (+Endurance Tests)

Power Cables

Control system from equipment to the CCC (Platform to test the software tools)

Example: RR77 tests

Short-circuit tests

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38.6

56.0 °C

40

50

FLIR Systems

An Infra Red analysis to see what a hand cannot feel at

less than 20cm !!!Loose connection

Systematic Infra Red (IR) survey

600A cables

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An Infra Red analysis to check everything is

OK

Systematic Infra Red (IR) survey

Y. Thurel

4 racks with 8 * [±600A;±10V]in UA 67

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What did we learn ?

Power converters are fulfilling specification but important tests to solve interface problems and coupling problem between circuits (e.g. MB and MQ, 600A circuits, EMC,…)

Continuous improvement of PC control and regulation software (FGC : V.99 to V.237)

The short circuit tests were essential to validate the power converters in their environment (AC, harmonics, cooling & ventilation, …)

Several 24h tests were done twice to confirm DC cabling modification, cooling & ventilations, bad connections, leaks,…

Measurement and Validation of the active and reactive power (P,Q) and THD (pt 4 not tested with RF; available P and Q should be confirmed by TS/EL)

Control and diagnostics of power elements from the CCC

To solve a lot of early failure (“défaut de jeunesse”), especially with the heat runs

TO BE READY FOR THE HARDWARE COMMISSIONNING

Short-circuit tests

A lot of groups worked together in the tunnel

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Hardware commissioning: Sector 7-8

Powering

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- PIC2 (Power Interlock test with PC connected to the magnets)

- Transfer Function Analysis- Power converter and Circuit set-up

(Setting of the current loop parameters) (PCC)

- Start-up procedure compatible with QPS

- Verification of the superconducting splices (PCS)

- Powering to Nominal of every circuit with intermediate level( PLI1… PLI4 => PNO)

- Check of the machine squeeze functions (PSQ)

- 24-hour run with all the circuits at nominal (PAC)

- General emergency stop test (AUG)

Powering tests

Converters connected to the magnets

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http://hcc.web.cern.ch/hcc/pp/

Powering Procedures

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Circuit TypeSector

LHC1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-1

13 kA 3 3 3 3 3 3 3 3 24

Independently Powered Dipoles 3 2 2 3 1 0 2 3 16

Independently Powered Quadrupoles 14 7 6 13 12 5 7 14 78

600A with Energy Extraction 23 27 28 24 23 27 27 23 202

600A Energy Extraction in Converter 14 20 20 14 14 20 20 14 136

600A no Energy Extraction 16 9 2 9 9 2 9 16 72

80-120A Correctors 50 37 22 33 33 22 37 50 284

TOTAL 123 105 83 99 95 79 105 123 812

Sector 7-8 HW commissioning: released circuits

Circuit TypeSector

LHC1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-1

60A Closed Orbit Correctors 94 94 94 94 94 94 94 94 752

Circuits powered from the arc

Limited Current: RB (2 kA), RQD (6.5 kA), RQF (6.5 kA) 3

Only RD2, Inner triplet dipole not available 1

Only RQ4 and RQ5 2

14 Line-N Circuits, 3 spool piece correctors & 2 MQTLH 19

Three Line-N Circuits 3

RCO and inner triplet correctors not available 0

Q4 and Q5 available correctors 7

Total of released circuit 35

Released: 78 R. Saban

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• Powering Tests – 20.04.2007 -> 06.07.2007 History http://hcc.web.cern.ch/hcc/schedule/History_S78_20070702.pdf

• Sector 78 Dashboard (108/199 circuits in Total) (http://p2n.web.cern.ch/p2n/dash/sector78.htm)

– Fully Commissioned: 44 circuits • 1 x [8kA,8V] converter (RD2) • 2 x MQM [6kA, 8V] converters (Matching Q4 & Q5 Quadrupoles)• 1 x [±600A,±10V] converter (RQS.L8B1)• 8 x [±120A,±10V] converters (Orbit Correctors + RCO.A78B1)• 32 x [±60A,±8V] converters (Orbit Correctors)

– Partially commissioned: 64 circuits• 1 x [13kA, ±180V] converter (Main Dipole) up to 2kA• 2 x [13kA,18V] converter (Main Quadrupole) up to 6.5kA• 15 x [±600A,±10V] converters up to 200A• 46 x [±60A,±8V] converters (Orbit Correctors)

Sector 78 – What did we test?

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1.9K

4.5K

Low current module 6kA & 600A leads

High current module 13kA & 6kA leads

Shuffling module

Vacuum equipment VAA

Connection to magnets

Jumper cryoconnection to QRL

SHM/HCMinterconnect

HCM/LCMinterconnect

Supporting beam

600A leads

6kA leads

6kA leads

13kA leads

Current lead chimneys

Removable door

Main dipole circuit powering

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RB successfully started with START_DIDT = 10A/s

The FGC regulates dI/dt by controlling dV/dt with a proportional controller

New open loop voltage ramp included until

I > 1% of I_MIN

Blocking voltage during Pre-Mag

Main dipole Power Converter Start Up [New algorithm]• Start up must avoid rapid voltage changes that can trigger the QPS• If current is less than 1% of I_MIN then a blocking voltage must be applied during the pre-mag

phase – this winds up the voltage loop integrators• This could result in an aggressive start up that could trip the RB QPS so ~6s open loop voltage

ramp is now included to make the start up smoother:

Q. King

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15.5 H

7 ppm (100 mA)

2 ppm (20mA)

3 A/s

350 A

45 V

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First current cycle (main dipole)27th June 2007 9h27 CET

7:20 7:30 7:40 7:50 8:00 8:100

500

1000

1500

2000[A]

Injection current

Imin

Fast discharge with switch opened (L/r 100 s)

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19:00 19:30 20:00 20:30 21:00 21:300

1000

2000

3000

4000

5000

6000

7000

Curr

ent

[A]

Quadrupole Circuits (RQF, RQD)

Dipole Circuit (RB)

Tracking between the three main circuits of sector 78

2ppm

Free-wheeling : L/r 23’000 s

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• RB decay from 350A takes more than 1 hour with the discharge switch closed

• New Switch Off algorithm will ramp down the current to 1% of I_MIN (< 4 A) before switching off (<40s)

• The algorithm will also be used for SLOW ABORT

Converter is switched off with V_REF = 2% of V_NEG

Voltage is reduced in proportion to the current to smoothly end the ramp to 1% of I_MIN

End of a Switch Off ramp on RB

dI/dt of ramp down is regulated to be -LIMITS.DIDT by controlling dV/dt with a proportional controller

Main dipole Power Converter: Power Off [New algorithm]

Q. King

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- Current loop robustness: L/2r to L/r

- Always: static and dynamicI1/2 < I2 < 2xI1

andI2/2 < I1 < 2xI2

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RQ4.L8B1 I_MEAS

RQ4.L8B2 I_MEAS

RQ5.L8B1 I_MEAS

RQ5.L8B2 I_MEAS

RQ4.L8B1 V_MEAS

RQ4.L8B2 V_MEAS

RQ5.L8B2 V_MEAS RQ5.L8B1 V_MEAS

0VClose to Limits

+

RQx.B1 RQx.B2

- + -

cable2cable3cable1

Squeeze tests (PSQ) : Q4 and Q5RQ4.L8B2 is close to limitNew optic function much improved (15min squeeze)All systems performed as calculated

With LHC Software Application LSA: generation of table (I,t) => dI/dt >> between pointsMQM control touchy during ramp down with 1-Quadrant converter=> Good Performance even if the limits are closed

D. Nisbet

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I_MEAS = About 1-2ppm pk-pk

1 ms

Vout

1300 A

1625 A

6500 A

Converter Operation during a sub-converter failure

[13kA,18V] converter : (4+1) x [3.25kA,18V] subconverters

Tests during 7-8 hardware commissioning

13 kA, 18V

3.25 kA , 18 V

3.25 kA , 18 V

3.25 kA , 18 V

3.25 kA , 18 V

3.25 kA , 18 V

At injection current : 860 A

Restart ofsub-converter 2

V. Montabonnet

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U_LEAD versus Current

-0.06

-0.05

-0.04

-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0.04

0.05

0.06

-60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60

Current [A]

Voltage across Leads [V]

Current Leads badly connectedResistive Current Lead Protection

R Lead Histogram

02468

10121416182022242628

0.0005 0.0006 0.0007 0.0008 0.0009 0.001 0.0011 More

R Leads [Ohms]

Fre

qu

ency

54 samples

V. Montabonnet

Power Converter

High Polarity

Low Polarity

Current lead

Current lead

Magnet

High polarity warm voltage tap

High polarity cold voltage tap

Low polarity cold voltage tap

Low polarity warm voltage tap

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U_LEAD versus Current

-0.06

-0.05

-0.04

-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0.04

0.05

0.06

-60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60

Current [A]

Voltage across Leads [V]

Current Leads badly connected

U_LEAD during Heat Run

-4.00E-02

-3.00E-02

-2.00E-02

-1.00E-02

0.00E+00

1.00E-02

2.00E-02

3.00E-02

4.00E-02

03.07.200718:00

03.07.200720:00

03.07.200722:00

04.07.200700:00

04.07.200702:00

04.07.200704:00

04.07.200706:00

04.07.200708:00

04.07.200710:00

04.07.200712:00

04.07.200714:00

Time

U_L

EA

D [

V]

2 Hours

Leads without Beam Screen Cooling

-1.50E-01

-1.00E-01

-5.00E-02

0.00E+00

5.00E-02

1.00E-01

1.50E-01

03.07.200719:00

03.07.200720:00

03.07.200721:00

03.07.200722:00

03.07.200723:00

04.07.200700:00

04.07.200701:00

Time

Vo

ltag

e ac

ross

Lea

ds

RCBH25.L8B1 U_LEAD_NEG RCBH25.L8B1 U_LEAD_POS RCBV25.L8B2 U_LEAD_NEG RCBV25.L8B2 U_LEAD_POS

Trip Level

Trip Level

Good Cooling Bad Cooling

Resistive Current Lead Protection

R Lead Histogram

02468

10121416182022242628

0.0005 0.0006 0.0007 0.0008 0.0009 0.001 0.0011 More

R Leads [Ohms]

Fre

qu

ency

54 samples

V. Montabonnet

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Heat-Run with 44 circuits (03.07 17:30 - 04.07 9:30)

RB.A78 (2kA)RQF.A78 (6.5kA)RQD.A78 (6.5kA)

RD2.L8 (6kA)RQ4.L8 (3.59kA)RQD.A78 (4.21kA)

RQS.L8B1 (550A) RCBYH4.L8B2 (72A) RCBYV4.L8B1 (72A) RCBYHS4.L8B1 (72A) RCBYVS4.L8B (72A) RCBYVS4.L8B2 (72A) RCBCH5.L8B1 (80A) RCBCV5.L8B2 (80A)

30 Closed Orbit Correctors (55A)

>16hwithout any fault

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Inner triplet powering (DFBX commissioning, nested converters: decoupling, loop robustness, protection with high time constant and no EE… )

Dipole powering up to 2kA : less than 3 % of the stored energy Quadrupole powering up to 6.5kA (30% of energy)

Free-wheel system at high current with large time constant (MB, MQ, IT,…)

Only one 600A circuit at nominal (RQS.A78 at 550A) !

High precision OK but low statistics Complete heat run at nominal current (1.1 GJ) Complete AUG test at nominal (partly done but no current in the

main circuits)

8kA

Q1 Q2 Q3

6kA

IF = I1 +

I2

IK =

I1

I2

Vcv

1Vcv2

±600A

Vcv3

I1

Q2

Sector 7-8: what was NOT done?

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Sector 7-8: what was not done?What can we do faster when powering for the next sectors ?

No ELQA at 80oK then no stop for the cool down Settings of the current loops (TFA done; to do again only if) and

more generally automatic FGC configuration Start-up of the converters compatible with QPS

100mV threshold for QPS (nominal) instead of 20mV (MPP for sector 7-8)

operating mode automated and parallel sequencing of tests diagnostic tools and Post-Mortem more stable test data recording tools quality assurance and progress follow up learning curve for event analysis

above all, the team is built and is performing wellDixit

HWC project leader

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Sector 7-8: what was not done?What can we not do faster the powering for the next sectors ? Qualification of the circuits at cold (ELQA)

(ELQA per DFB and no more per circuit type. Will be faster)

Sequence of qualification of the QPS (FastPa and quench).

Quench recovery time at high current will be a key parameter

Magnet training above 11kA

350A

PIC2Injection 760A

EESPA FPA

Quench2 kA

Loss PP

EEQuench

6 kA

8.5 kA

12 kA

RB Circuit

Quench

Quench

Quench

PM Analysis for each steps

“No shortcut or it’ll be the

Mess”

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5/12/200726 - 27/11/2007

A

V

3610A

Last news from the field : Q6.R4 (MQY) powering to nominal (5.12.2007 pm)

3610A

Unbalanced Quench

NominalUnbalanced1 Unbalanced2Quench

Nominal

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Synchronisation from the database to an FGC

1. When an FGC is power-cycled or reset it raises the SYNC_FGC flag to request to be synchronised

2. The FGC Config Manager sees the request and sends commands to the FGC to read the inventory of equipment in the converter

3. The Manager sends the inventory to the database and retrieves the related configuration

4. The Manager sends commands to the FGC to update its configuration

5. The Manager clears the FGC’s synchronisation request

FGC Config Manager

PO ControlsDatabase

x ~80

<= 30

WorldFIP bus

Inventory Configuration

SYNC_FGCrequest

Statusdata

Command/ response

FGC gateway

FGC FGC FGC FGC FGC FGC FGC FGC

S. Page

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Synchronisation from an FGC to the database

1. A user updates the configuration in an FGC by sending the relevant commands, then sets the SYNC_DB flag

2. The FGC Config Manager sees the request and sends commands to the FGC to read the configuration

3. The Manager stores the configuration changes in the database

4. The Manager clears the FGC’s synchronisation request

SYNC_DBrequest

Configuration

FGC Config Manager

PO ControlsDatabase

x ~80

<= 30

WorldFIP bus

Statusdata

Command/ response

FGC gateway

FGC FGC FGC FGC FGC FGC FGC FGC

S. Page

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RB, RQD, RQF synchronized ramp

A B

FGC

Electronics

Sigma-Delta 22b ADC

A B

A B

FGC

Electronics

Sigma-Delta 22b ADC

A B

A B

FGC

Electronics

Sigma-Delta 22b ADC

A B

RB.A78 RQF.A78 RQD.A78Tracking Tests RB-RQF-RQD

D. Nisbet

Test Method: I Channel A swappedRegulation with I Channel B