R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015

BI.DIS10: Magnets & generators

2

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 3

Contents

- BI.DIS system parameters- System and pulse generator description- Test results- Final design- Planning, Resources, EVM- Conclusions

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 4

BI.DIS system parameters

Parameter Unit ValueDeflection angle at 160 MeV(vertical)

mrad DIS0: 3.77DIS1: 4.23DIS2: 3.84DIS3: 3.4DIS4: 3.97

Kick flat-top duration µs DIS0: 20DIS1: 170DIS2: 320DIS3: 470DIS4: 620

Kick rise time (1-99)% µs ≤ 2

Kick flat-top ripple (p-p) % ≤ ±1

Magnet current A ~ 1000 A

PFN impedance Ω 6.25

PFN voltage kV 6.25

Repetition rate Hz 1.1

5.4632 5.5042 5.5452 5.5862 5.6272 5.678

x 104

-80

-60

-40

-20

0

20

40

60

80

Drift Space [mm]

Am

plitu

de [m

m]

PSB Injection Geometry for DIS Magnets for D = 0

6.024

-4.78

-12.1

-20.2

5.4 5.6 5.8 6 6.2 6.4 6.6

x 104

-300

-200

-100

0

100

200

Drift Space [mm]

Am

plitu

de [m

m]

~150µs

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 5

System and pulse generator description

• 5 magnets in one vacuum tank• 5 Pulse Forming Networks 6.25 Ω (one per magnet) + 1 spare• PFN voltage up to 10 kV ( ~ 7 kV nominal with H- operation)• IGBT switch (2 × 6.5 kV device in series)• fixed duration (different for each PFN, max 620 µs)• short-circuited magnet• recuperation of a large fraction ( > 50 %) of the PFN stored energy (1270 J)

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 6

BI.DIS10 vacuum tank

Tank (with 5 magnets) under vacuum in SAL6 test cage ready for connection to pulse generator.Pressure ok: 2e-9 mbar.TE-VSC will re-test the water circuit before their final acceptance.Spare tank to be tested later.ENG. Spec: EDMS 1454374

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 7

Prototype pulse generator tests results

• Impedance ~6.25 Ω chosen for 2 µs rise time.• 2×6.5 kV IGBTs in series for operation at ~7 kV/1000 A.• Switches: ABB or Hitachi are suitable.• 60 cells for 620 µs pulse (60 capacitors of 1 µF) to fill the

available space and have a minimum flat-top ripple.

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 8

Prototype pulse generator tests results

Magnet current (= Kick)

Voltage to reach 1000 A is 7 kVdue to resistive losses and rising edge shape adjustment (and optimisation) leading to a PFN impedance near 7 Ω.

Rise-time ≤ 2 µs achievedwith more than 500 ns margin.

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 9

Prototype pulse generator tests results

Ripple ≤ ±1 % achievedwith foreseen improvement to ≤ ± 0.5 % in final installation.

Magnet current (= Kick)

Pulse lengths from 170 to 620 µsachieved with 1, 2, 3 and 4 capacitor rows.20 µs still to be done.

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 10

Pulse generators final design

Each cabinet rack contains two separate PFNs of 60 L-C cells maximum

L-C cell

PFN RackSwitch rack

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 11

Pulse generators final design

Each PFN cabinet half is “hermetic” and has an integrated automatic fire detection and CO2injection system.Pressure relief valves have to be installed to limit the CO2 pressure in the rack.

Pressure relief valve Front cell

IGBT Switch

Earthing device

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 12

Pre-series pulse generator

Pre-series status 17 November 2015

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 13

BI.DIS Prototype

Definitive Design Type Test Performance Reliability Operational conditions Safety Preliminary Controls

Functional Spec.

First Prototype

Design Update Test

Improved Design

Review

12/2014

07/2015

R

ea

lisa

tio

n a

nd

De

ve

lop

me

nt

• Proof of Concept

03/2016 Engineering Spec.• Start of Series

Production

• Definitive Design

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 14

Present Status and tests still to be performed

STATUS• PFN mechanical design complete at 95 % (CATIA 3D models and 2D

fabrication drawings). In stand-by due to the illness of P. Faure.• One full pre-series almost ready for test.• Two IGBT types selected among four manufacturers to meet the pulse

required rise time• Tests with full pulse length (620 ms) and nominal required current (1000

A) performed.• Fire extinguisher test performed.• Final three cabinets ready for delivery by the manufacturer.• More than 60 coils ready for the series.

NEXT TEST

Full operational conditions with closed cabinet to see if we have thermal issues. The departure of Rodolphe will slow down the restart.

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 15

BI.DIS Generator Assembly Schedule

Mar Jun Jul Aug Sep Oct Nov Dec 2017

Start Series Production

1st Rack ReadyEnd April

Ready to installEnd December

2 weeks (FSU!)Cabling

1 weekCell Tuning

2 weeksVerification Test

Feb

1st Definitive Generator

2 weeks (2 x FSU!)Rack Assembly

MayApr

9 w

eeks

MarchStart 2nd Rack

June

1 weekDisassembly

Start 3rd RackSeptember

2nd Rack ReadyEnd July

3rd Rack ReadyNovember

Fast Interlock

Trigger System

2nd Rack

Fast Interlock and Timing

Controls Test 3 weeks

3rd Rack

Validation 2 weeks

9 weeks

9 weeks

1 week

1 week

1 week

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 16

Resources for 2016 (FPS only)

1. Material to be ordered and delivered in 2016 (6 PFNs)• Mechanical components: 100 kCHF• Electrical components: 80 kCHF• Miscellaneous: 20 kCHF

Total: 200 kCHF

2. FSU • Coil manufacture : 35 man.week• PFN cabinet assembly: 18 man.week

Total: 53 man.week

3. CERN FTE• Drawings update and orders: 0.3• Assembly: 0.4• Supervision and tests: 1.3

Total: 2 FTE

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 17

EVM: Provide BI.DIS magnets

Year 2008 2009 2010 2011 2012 2013 2014 2015

PV 131 149 77 146 60 0 0 0EV 0 193 3 263 103 0 0 0AC 167 158 38 56 20 0 0 6

Metrics per year in kCHF

Cumulative metrics per year in kCHFYear 2008 2009 2010 2011 2012 2013 2014 2015

PV 131 280 356 502 562 562 562 562EV 0 193 196 459 562 562 562 562AC 167 324 362 418 438 438 438 444

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 18

EVM: Provide BI.DIS pulse generator

Year 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

PV 0 0 63 85 85 165 389 933 347 149 38EV 0 0 0 33 201 170 383 434AC 3 31 60 135 82 166 213 368

Metrics per year in kCHF

Cumulative metrics per year in kCHF

Year 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

PV 0 0 63 148 233 399 788 1721 2068 2217 2255EV 0 0 0 33 234 405 788 1221AC 3 34 94 230 312 478 691 1059

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 19

Conclusion

The new BI.DIS generators are entering their production phase but the full pre-series version still has to be validated.

Test of the full pre-series one will start hopefully this year for completion early next year.

The goal of having the full system ready for installation end of 2016 should be met assuming that the necessary resources will be available at the right moment. The management has to set priorities accordingly.

THANK YOU FOR YOUR ATTENTION!

R. Rosol, L. Sermeus, T. Stadlbauer , TE-ABT LIU review, 20 November 2015 20