SLAC Accelerators Power Electronic System Operation for

Reliability

F. Rafael04/13/2011

Agenda

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• Overview• PCD Organization• Tools• Reliability metrics and numbers• Accelerator Improvement Programs• Design for reliability• Conclusion

Overview

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PCD Sustaining Engineering • SSRL (SPEAR3)• LCLS (1/3 LINAC)• NLCTA• FACET (2/3 LINAC)

SLAC Organization

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SLAC is now a multipurpose laboratory for astrophysics, photon science, accelerator and particle physics research.

Service Level Agreement (SLA)

Machine Value CommentsPerform Period FY One YearScope Equipment

coverageCoverage

Availability >99% Critical Electrical Equipment

Contact Personnel

Syst. Managers

Includes Escalation Policy

Budget FTEPower Eng.Power TechEng. Service

M&S $k

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Core Teams and PCD-SE

Power Conversion Department - PCD

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SE

Power Conversion Department - PCD

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Work Planning & ControlPlan the job right or don't do it!

Work Planning and Control (WPC) is a standardized process used to understand the scope of work, identify qualified workers, evaluate & control hazards, communicate hazards & controls to workers, authorize, coordinate & release work and perform it within established controls.

Power Conversion Department - PCD

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TOOLS:

PEM Work Flow

24/7 coverage

Power Conversion Department - PCD

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Tools: CATER

Power Conversion Department - PCD

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Tools: E-LOG PEM

Power Conversion Department - PCD

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Tools: Documentation – SODA*

Power Conversion Department - PCD

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Tools: Documentation - CAPTAR

Power Conversion Department - PCD

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Tools: Documentation - Inventory

Power Conversion Department - PCD

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TOOLS: EEIP

SLAC – Electrical Equipment Inspection Program – EEIP Primary deployed for safety, has demonstrated

improvement in reliability and used as part test acceptance and QA.

Based on • UL – 508A – Industrial Control Panels • UL – 61010A-1 Electrical Equipment for Lab. Use

http://www-group.slac.stanford.edu/essg/eeip/program.htm

Electrical Equipment Inspection Program- EEIP

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Electrical Equipment Inspection Program- EEIP

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Electrical Equipment Inspection Program- EEIP

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bonding conductor

Table 15.1 of UL 508A

Spacing

Table 10.1 and Table 10.2 of UL 508A

Electrical Equipment Inspection Program- EEIP

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Code Violation:NEC2008 - Section 110.14(A): Terminals for more than one conductor … shall be so identified

Poor workmanship:UL508A - 29.3.6Wiring Methods: no loose strands protruding from the connection.

Reliability Metrics

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Events

TimebeamScheduledMTTF

__

Events

TimeDownUncheduledMTTR

__

TimeBeamSchedule

TimeDownUncheduledtyAvailabili

__

__1

LCLS SPEAR3MTTF 84.1 (Hrs) 588 (Hrs)

MTTR 0.64 (Hr) 1.45 (Hr)

Availability 99.24% 99.75%

Power Conversion Department Numbers

2010 – 2011 Run

Details from LCLS run was covered Monday presentation

Reliability Metrics – SPEAR3 Breakdown per System

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Reliability Metrics

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Reliability Metrics

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Accelerator Improvements Program – AI’s

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LCLS Modulator failures current account for 66% of the power electronics total

Accelerator Improvements Program – AI’s

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1/3 of LINAC ($2 MI)• 10 Sectors• 8 Modulators per SectorModernization• Cabinet 1

• AC input• IOC’s• Interlocks

• Cabinet 2 and 3• PFN• Switch (thyratron)

Successful implementation of both upgrade projects along the length of LCLS is expected to reduce modulator failures by 60%.

Design for Reliability

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Paul Bellomo and Dave MacNairPaul Bellomo and Dave MacNair SLAC National Accelerator Laboratory SLAC National Accelerator Laboratory

ARW Vancouver, CanadaARW Vancouver, Canada January 26-30, 2009 January 26-30, 2009

Non-redundant - PEP II, SPEAR 3, LCLS (1994 – 2006)

• Power supply quantity is hundreds, not thousands

• Power supply availability budget is modest 98%

• Non-redundant supplies satisfied availability budget

• Redundant power systems not readily available from industry

• Redundant systems would not fit within cost and schedule constraints

Redundant - KEK ATF 2 (2006 – 2008)

• Mock-up of ILC Final Focus accelerator

• Magnet power supplies ILC-like

Design for Reliability

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KEK ATF 2 Approach By P. Bellomo & D. MacNair

N+1 Power Modules

(38)

Ethernet PS Controller

(38)

AC Input

Ethernet-EPICS I /O

Power Supply Rack

MagnetTransductor

(76)

Current feedback

Bulk Voltage Source15kW

(6)

Water temperature

InterlockClock + DC reference+ Fault signals

DC reference+ Fault Signal

Interface BoardClock/FaultProcessing

(38)

Cable Resistance

200A

Bulk Voltage Source PLC

(1)

Ethernet-EPICS I /O

On/Off, Vo

Design for Reliability

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Goals•All components N+1 modular and redundant

•Power module hot-swappable

•Unipolar or bipolar output from a single unipolar bulk voltage source

•Imbedded controller with digital current regulation

•Capable of driving superconducting magnets

•High bandwidth for use in BBA or closed orbit correction systems

•High stability and precision output current

•High accuracy read-backs

•Scalable to higher output levels

Applications

•ILC and other future accelerators

Conclusions

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PCD has successfully demonstrated using Sustaining Engineering model accomplish target goals either to support users accelerator program and experimental facilities as well. The same PCD model can accommodate Accelerator Improvements Programs and new developments for futures requirements specification, targeting High Availability Systems.

Last but no least…

Now available @ IKEA

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Thank you!