310312_Current_Pump_Inductor.pdf

PIP-II Gamma-t Power Supply SPECIFICATION Charge Pump Inductor #9570-ES-310312

Table of Contents

1 INTRODUCTION

1.1 Description

1.2 Configuration

2 SCOPE OF WORK

3 INDUCTOR SPECIFICATIONS

3.1 Inductance, Low Excitation

3.2 Inductance, Saturation

3.3 Current

3.4 Voltage

3.5 DC Resistance

3.6 Impedance, High Frequency (1 kHz), Low Excitation

3.7 Insulation Rating

3.8 Corona, Coil to Core/Ground

3.9 Temperature Rise

3.10 Operating Lifetime

4 MECHANICAL REQUIREMENTS

4.1 Dimensions

4.2 Terminals

4.3 Coil Construction

4.4 Orientation

4.5 Environmental Conditions

4.6 Cooling

4.7 Nameplate Information

5 TESTS BY MANUFACTURER

5.1 Inductance, Impedance, Low Excitation

5.2 Inductance, Saturation

5.3 DC Resistance

5.4 Hipot Test

5.5 Corona test

6 ACCEPTANCE TESTS BY FNAL

6.1 Inductance and Impedance

6.2 Inductance, Saturation

6.3 DC Resistance

6.4 Hipot Test

6.5 Corona Test

6.6 Ring Test

7 APPENDIX A

7.1 Bid Submittals

7.2 Design Reviews

Table of Figures

Figure 1: Gamma-t Schematic Diagram (Simplified)

Figure 2: Vdiff, I, Normal Operating Conditions

Figure 3: Terminal Voltages, I, Normal Operating Conditions

1 INTRODUCTION

1.1 Description

This specification is for a Charge Pump Inductor in a Pulsed Power Application, referred to as the “Gamma-t Power Supply.” The basic circuit is shown in Figure 1.

1.2 Configuration

The Gamma-t power supply is a capacitor-discharge pulser that generates a ±878 A peak half-cosine wave pulse in a triplet string of quadrupole magnets. The pulse length is 0.75 ms and repeats every 0.65 s. There will be a total of four of these supplies discharging into four separate inductive quadrupole triplet loads.

The circuit works by charging a 150 mF capacitor bank and then discharging it into the magnet load through three IGBT switches. IGBT1 and IGBT2 will close simultaneously, charging the magnet load, the charge pump inductor, and the jump capacitors.

After 5ms, IGBT1 and IGBT2 will open simultaneously, creating a resonant circuit between the jump capacitors and the magnet load that will generate a half-cosine wave from +878 A to -878

A in 0.75 ms. This causes the energy in both the charge pump inductor and magnet load to transfer to the jump capacitors.

Once the voltage of the jump capacitor reaches 0V, IGBT3 is closed, forming an RL circuit. This then allows the current to decay through natural losses of the cable and magnet.

The purpose of the charge pump inductor is to offset the energy losses of the jump transition by storing energy in its magnetic field. This energy is supplied to the Cjump capacitors allowing the current to reach its peak negative amplitude of -878 A for a symmetrical transition.

2 SCOPE OF WORK

The vendor shall manufacture and test the inductor, Lpump, in Figure 1.

The vendor shall supply Material Safety Data Sheets on any required materials.

Figure 1: Gamma-t Schematic Diagram (Simplified)

C

DC

C P S

C

C m

I T m

C C

S a th

G a a

3 INDUCTOR SPECIFICATIONS

See supplemental plots (Figure 2 and Figure 3) for normal operation.

Steel core or proposed manufacturer alternative are acceptable.

3.1 Inductance, Low Excitation

4mH ±5% at 1 kHz, 0 A average

3.2 Inductance, Saturation

No less than 90% of nominal inductance (see Section 3.1) at 1 kHz, 250 A peak

3.3 Current

See Figure 2 – Figure 3

20 A RMS

250 A Peak

3.4 Voltage

See Figure 2 – Figure 3

Terminal to Terminal Voltage ±3.5 kV peak

Terminal-to-Core/Ground Voltage ±2.0 kV peak

3.5 DC Resistance

Less than 0.3 Ω at 25 °C

3.6 Impedance, High Frequency (1 kHz), Low Excitation

The impedance of the inductor at 1 kHz shall be within 5% of 16.67 times the 60 Hz impedance.

The inductor shall have no self-resonances below 3600 Hz

3.7 Insulation Rating

The coil insulation shall be designed to meet the voltages specified in section 3.4

3.8 Corona, Coil to Core/Ground

The corona extinction voltage shall be greater than 2.0 kV RMS with respect to ground or the corona inception voltage shall be greater than 2.5 kV RMS with respect to ground when both terminals are tied together.

3.9 Temperature Rise

The average coil temperature rise shall not exceed 100 °C operating under the conditions specified in sections 3.3 and 3.4 The coil hot spot temperature shall be coordinated with the insulation temperature rating/class.

3.10 Operating Lifetime

>195,000 hours of continuous operation

>109 nominal pulses

4 ECHANICA REQUIRE ENTS

4.1 Dimensions

The Inductor, including any mounting hardware, shall be able to fit in a space of absolute maximum dimensions:

24 in x 18 in x 10in (LxWxH)

4.2 Terminals

The inductor shall have two terminals.

Each terminal shall have two holes of 1/4 inches diameter, /8” s ac etwee h es

(center-to-center).

These holes are to accommodate Burndy YA4C2 compression lugs (or equivalent).

4.3 Coil Construction

The coil shall be constructed of copper

4.4 Orientation

The inductor shall be able to operate while mounted vertically or horizontally

4.5 Environmental Conditions

Ambient Temperature 20 to 50 °C (0 °C for Storage) Relative humidity 20% to 90%

4.6 Cooling

The inductor shall be natural convection air-cooled. Neither water nor forced air cooling is allowed.

4.7 Nameplate Information

The minimum information to be on the nameplate is:

- Name of Manufacturer

- Customer Specification Number 9570-ES-310312

- Manufacturer’s Serial Number

- Year of Manufacture

- Inductance (Measured) at 60 Hz and 1 kHz

- Resistance (Measured) at DC

- Rated Peak Voltage

- Rated RMS Current

- Rated Peak Current

- Weight

5 TESTS Y ANUFACTURER

Acceptance test shall be performed at the vendor's plant prior to shipment to prove that the equipment meets all the specifications.

5.1 Inductance, Impedance, Low Excitation

Measure and record the inductance and impedance for a frequency sweep from DC to

3600 Hz.

The inductor shall have no self-resonances in that frequency range and the inductance and impedance at 1000 Hz shall meet requirements of sections 3.1 and 3.6.

5.2 Inductance, Saturation

Incremental inductance shall be obtained at current values that allow verification of nominal inductance (section 3.1) and the saturation inductance (section 3.2).

5.3 DC Resistance

Measure and record the DC resistance of the inductor. It shall meet requirement 3.5

5.4 Hipot Test

The coil shall be hipotted to 3.5 kV DC for 1 minute with respect to ground with both terminals tied together and the core tied to ground. Measure and record the leakage current at 30 seconds and at 1 minute, humidity, and ambient temperature.

5.5 Corona test

Measure the corona inception voltage (>100 pC peak) and extinction voltage (< 50 pC peak) with respect to ground with both terminals tied together and the core tied to ground. This shall meet the requirements of Section 3.8

6 ACCEPTANCE TESTS Y FNA

The following tests will be performed by Fermilab before acceptance:

6.1 Inductance and Impedance

Measure inductance and impedance for a frequency sweep from 60 Hz to 3600 Hz.

The inductor shall have no self-resonances in that frequency range and the inductance and impedance at 1000 Hz shall meet requirements of sections 3.1 and 3.6.

6.2 Inductance, Saturation

Incremental inductance shall be obtained at current values that allow verification of nominal inductance (section 3.1) and the saturation inductance (section 3.2).

6.3 DC Resistance

Test of the DC resistance shall meet requirement 3.5

6.4 Hipot Test

The coil shall be hipotted to 3.5 kV DC with respect to ground with both terminals tied together and the core tied to ground for 1 minute. Measure and record the leakage current at 30 seconds and 1 minute, humidity, and ambient temperature.

6.5 Corona Test

A Corona (Partial Discharge) Test shall meet requirement 3.8

6.6 Ring Test

A ring test consisting of charging up a capacitor and ringing the full voltage of section 3.4 across the inductor terminals shall be done to verify no turn-to-turn shorts.

Figure 2: Vdiff, I, Normal Operating Conditions

Figure 3: Terminal Voltages, I, Normal Operating Conditions

Cycle repeats every 0.65s

Cycle repeats every 0.65s

7 APPENDIX A

7.1 Bid Submittals

7.1.1 Exceptions to the Specification

7.1.2 Lifetime Estimate

7.1.3 Inductor Parameters

a) Inductance at DC and 1 kHz

b) Insulation Voltage rating

c) Peak and RMS Current ratings

7.1.4 Method for estimating inductance, frequency response and voltage rating

7.1.5 Method for testing for saturation

7.1.6 Sketch of the proposed inductor including:

a) core dimensions

b) gap location and number of gaps

c) lamination thickness

d) core material

e) wire size

f) turns

g) coil dimensions

h) coil spacing to gap

i) insulation temperature rating

j) weight

7.1.7 Will all tests in Section 5 be performed in house? If not, mention a list of tests that will be outsourced.

7.1.8 General description or outline of quality assurance program.

7.1.9 Estimated delivery time for the choke.

7.1.10 List of experience with making similar products

7.2 Design Reviews

A design review is required before construction. All quality inspections records signed by the Q a ty t I s ect sha e ava a e f e m a ’s ev ew f eq este

7.2.1 w ays w e eq e f N ’s ev ew f th mecha ca and electrical drawings.