4. Enclosure 1, Attachment (B) SPEC C-AD_Cyclo.pdf

Brookhaven National Laboratory Number:spec_CAD-1369 Brookhaven Science Associates Date:2/20/25

Collider Accelerator Department Revision:

ECN #:

C-AD SPEC Template V2

SPECIFICATION

for a

Power Control and Regulating System for the AGS Motor Generator Set

(Cycloconverter)

Prepared by

Approved by

Jon Sandberg/C-AD Chief Electrical Engineer

Approved by

Ioannis Marneris/ AGS PS Group Leader

Approved by

Edward Bajon/ Electrical Engineer

Wolfram Fischer/C-AD Department Chair

Approved by ______________________________________________________ Rob Michnoff / Acting Division Head

Approved by _______________________________________________________ David Passarello / Configuration Management

3/25/2025

3/25/2025

3/25/2025

3/25/2025

3/25/2025

3/25/2025

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

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REVISION HISTORY

REV DESCRIPTION DATE AUTHOR ECN # APPROVED BY

1 First Issue 01/20/2025 Jon Sandberg N/A See cover page.

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CONTENTS

Contents

1 SCOPE

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Overview

3.1.0 Basic Description

3.1.1 Frequency Synthesis and Synchronization

3.2 Cycloconverter Power Supply

4 Feedback Loops

5 Protective Devices and Circuitry

6 Controls 7 Test Points 8 Instrumentation 9 Electrical Requirements 10 Mechanical Considerations 11 Markings and Serialization 12 AcceptancTesting(factory) 13 Installation 14 Final Acceptance Testing 15 Substitiutions 16 Preparation for Delivery 17 Smoothing Inductor Requirements 18 Existing Transformer Data 19 Cycloconverter Requirements 20 System Specific Data 21 Induction Motor Data Appendix index Appendix A Appendix B Appendix C Appendix D Appendix E doc number Page 6 of 29

1 SCOPE

This specification defines the technical requirements for a power controller/regulator (cycloconverter) used to regulate the input power to a 9 MW wound rotor induction motor, which drives a 95 MVA salient pole Generator. The synchronous speed of this machine is 1200 rpm. The power regulator will be referred to as the cycloconverter in this specification. This cycloconverter will be used for the Alternating Gradient Synchrotron (AGS) Accelerator at Brookhaven National Laboratory (BNL), located in Upton NY, 11973. BNL is managed by Brookhaven Science Associates (BSA). This document defines the technical specifications for this cycloconverter.

1.1 Background

The AGS contains a string of 240 magnets (0.75 Henries, 0.26 Ohms total load) which are continuously cycled from several hundred Amperes to a flattop of 6150 Amperes D.C, which can be held for up to 4 seconds, and then ramped down to a few hundred amperes. The rise and fall time of the waveform is approximately 600 msec. each. This will be done at a repetition rate of from one (no flattop) to six seconds. In order to buffer the incoming A.C. power lines from this large pulsating load, the D.C. (rectifier/inverter) power supply, which energizes the AGS magnets, is fed from a Motor Generator (MG) set. The input power drawn by the motor is controlled by a cycloconverter feeding the motor’s rotor windings. The cycloconverter controls the A.C. input power to the motor by dynamically controlling the motor rotor currents. This allows control of both the real and reactive power supplied by the utility. The reactive power is required to be as close to zero as possible for all cycles. The magnitude of the average real power required changes depending on the chosen cycle but remains constant throughout a given cycle. The input power is held constant at the level required to make up all the losses during a cycle. The load power fluctuations are supplied or absorbed by changes in the speed of the rotating mass. The average input power requirements can change from between 1 MW and 9 MW. The input power is controlled by a cycloconverter and its associated electronics. If the input power to the motor is exactly equal to the power losses within a cycle the speed of the motor will be the same at the beginning and end of each cycle. Different physics objectives require the cycles to vary but a particular operating cycle is run for many hours or even days before changing. A long string of these identical cycles is referred to as a super cycle. The power reference for a super cycle remains constant during its operations.

1.2 Definitions/Acronyms

ABL As-Built Listing AGS Alternating Gradient Synchrotron ANSI American National Standards Institute ASME American Society of Mechanical

Engineers ATP Acceptance Test Procedure Cyclo Cycloconverter Power Regulator

FDR Final Design Review NEC National Electric Code NFPA National Fire Protection Association NRTL Nationally Recognized Test Laboratory PDR Preliminary Design Review doc number Page 7 of 29

2 APPLICABLE DOCUMENTS

The following specifications, standards and drawings form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents shall be that in effect on the date of the solicitation or contract. Exceptions must be approved in writing by BSA.

Document Number Document Title

D04-M-2409sow Statement of work for a power control and regulating system for the AGS motor generator set (cycloconverter)

Code of federal Regulations Title 29,Section 1910

OSHA General Industrial Safety and Health Regulations and Standards

NEMA SG Indoor Power Switch Gear

IEC 478-3 Level c Reference levels of conducted electromagnetic interference (EMI)

IEC 1000-4-4-Level 2 Electric fast transient/burst immunity test

IEC 1000-4-4 Level 2 Immunity to conducted disturbances, induced by radio-frequency fields

NFPA 70 National Electric Code

ANSI/IEEE C 57 Distribution and Power Transformers

UL-1581-1080 VW-1

Flame Test Flammability Test for Cable Insulation

3 REQUIREMENTS

3.1 Overview

3.1.0 Basic Description

The following is a description of the AGS Main Magnet Power Supply together with its existing cycloconverter.

The AGS ring magnets are powered by 24 pulse thyristor-controlled AC to DC converters powered from voltage step down phase shifting transformers, fed from a three-phase synchronous generator. The generator is driven by a 9 MW wound rotor induction motor. The motor rotor is wye connected and all three phases, plus the neutral point, are brought out via four full current slip rings and associated carbon brushes.

The cycloconverter connects to the rotor windings through these brushes.

During the run-up and run-down phase of the MG set the motor current and speed are controlled by a liquid rheostat in the rotor circuit. When turning on, once the machine has reached a slip of approximately 2%, the cycloconverter is switched on-line and after a short time delay the liquid rheostat is switched out of the doc number Page 8 of 29 circuit. When turning off, the liquid rheostat is first driven fully in and then the rheostat is connected to the rotor circuit and after a time delay the connection to cycloconverter is opened. The requirements for handoff between the liquid rheostat and the cycloconverter must be specified by the Contractor. At no time is the motor rotor to be open circuited during this process. The machine is only pulsed into the magnet load when running from the cycloconverter.

The cycloconverter shall operate in a mode which makes the total input power equal to the power lost in each cycle. Therefore, the energy stored in the rotating mass will be the same at the beginning of each cycle and each cycle will begin with the same rotational speed. BNL will supply the power reference for each cycle. Super cycles may change during operations and the cycloconverter will be commanded to change the incoming power in anticipation of any new super cycle. The power reference will not be recalculated or changed during a super cycle. While the change in speed and energy losses for different super cycles will be different the speed at the beginning of each cycle within the super cycle shall be constant. The speed at the beginning of each cycle shall be controlled by a local adjustment on the cycloconverter. This control is to set the dwell speed and will generally not be varied during operations.

The motor shall operate both above and below synchronous speed and the beginning speed shall be settable above or below synchronous speed by +/- 2%.

The present cycloconverter is made up of two antiparallel six pulse thyristor bridges per rotor phase. Either thyristor or switch mode devices such as IGBT’s may be proposed for the new cycloconverter but the Contractor shall show in their proposal that the proposed design will present no unwanted high frequency components to the motor rotor windings. The winding insulation on the motor dates from the mid 1980’s so the rate of rise of the rotor voltages must be considered if switch mode supplies are proposed.

The Contractor supplied regulator for the cycloconverter will consist of a fast-inner loop which regulates the rotor currents and a slower outer loop which modifies the reference to the current loop based on the real power error signals. The induced rotor currents are sinusoidal in nature at the slip frequency. The signals sent to the cycloconverter from the Contractors supplied controller shall be synthesized at the correct phase, amplitude and frequency, to properly control the input power to the motor, both real and reactive. These signals will change dynamically with motor speed and slip. In order to measure the slip and synchronize the rotor currents, a hermetically sealed optical shaft encoder and DC tachometer shall be mounted on the machine shaft. The shaft encoder has to be indexed to the position of the motor rotor relative to the motor stator. The contractor shall supply the shaft encoder which shall be designed to be installed on the existing equipment without modification to the machine’s shafts.

The Contractor shall supply real and reactive power transducers and current transformers to measure the total power (stator plus rotor) and to provide a rotor current feedback signal as required. The slip, shaft synchronization, incoming power, and power factor shall be measured and displayed. Circuitry will be necessary to synthesize the required injected rotor currents phase, magnitude and frequency. The Contractor shall supply all equipment needed to synthesize the correct rotor current reference signals given the BNL power reference. BNL shall be responsible for mounting the various transducers on the existing equipment, but the Contractor shall work closely with BNL to supply devices which are compatible, both electrically and mechanically, with the existing system.

The power regulator determines the average power drawn by the motor from the line. As the instantaneous load varies during the cycle, the difference between it and the average power causes changes in the stored energy of the rotating mass of the motor generator set. This is exhibited by a decrease in the rotational speed during rectify and an increase in speed during invert of the magnets power converters, but the regulator ensures a constant speed at the start and end of every cycle. This is a desirable effect which forces changes in the load power to be taken from the energy stored in the rotating mass rather than from the utility. If the energy supplied from the line balances the energy dissipated in the load for each cycle the speed will be reproducible from cycle to cycle.

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3.1.1 Frequency Synthesis and Synchronization.

The injected rotor currents must be at slip frequency. The portion of the current in phase with the stator voltages determines the real motor power and the portion in quadrature with the stator voltages determines the reactive power drawn by the motor (set to zero). Therefore, the rotor currents must be synthesized so that they are always in phase with the stator voltages. It is therefore necessary that the slip frequency be measured and that this information be used in conjunction with the magnitudes of the real and reactive power error signal to synthesis the reference for the rotor current regulating loop. It is also necessary that the relative phase of the naturally occurring rotor currents be referenced to a marker on the shaft encoder.

This information can be used to synchronize the phasing of the synthesized rotor currents with that of the stator voltages. It should be noted that as the machine passes through synchronous speed the phase rotation of the injected rotor currents must change.

The switch gear used on the existing cycloconverter system shall be used. The existing transformer shall not be reused.

The Contractor shall specify the external wiring required, wire schedules, plumbing requirements to BNL so thet BNL can properly install and connect the power regulator and associated equipment.

The Contractor shall provide all cables internal to the supplied equipment and all wiring between the equipment racks.

3.2 Cycloconverter Power Supply

3.2.1 The cycloconverter shall supply currents at the correct magnitude, frequency, and phase, to control the input power and speed of motor by controlling the motor rotor currents. The converters shall operate without circulating current. The converters shall be capable of operating as bipolar, four quadrant units over their entire operating range. Single semiconductor cells shall be employed as the switching element in each bridge leg. Fuses shall be used for protection the semiconductors either in series with individual semiconductors or on each supply line. While water cooling is preferred, forced air cooling is acceptable.

3.2.1.1 Overtemperature devices.

Overtemperature devices, with the appropriate electrical isolation, shall be mounted on heat sinks. All parallel cooling paths shall be individually monitored.

3.2.1.2 The status of each fuse shall be monitored and annunciated. Opening of a fuse shall trip off the converter/inverter and shall generate an appropriate interlock. Electrical isolation of the fuse monitoring circuitry is mandatory.

3.2.1.3 All low-level triggering circuitry shall be properly isolated either by pulse transformers or by fiber optics.

3.2.1.4 Since the cycloconverter is to operate in a non-circulating current mode, the current in the forward bridge must go to zero before the current in the reverse bridge begins and vice versa. The period of time both bridges are off is called the blanking time. This time shall be specified in the Contractor’s proposal.

3.2.2 Semiconductors

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3.2.2.1 For the purposes of this specification the peak operating voltage of any device is the maximum voltage (DC or repetitive transient) which will appear across the device during any portion of a normal operating cycle.

3.2.2.2 The peak inverse voltage rating (PIV) and peak forward voltage rating (PFV) of all power semiconductors shall be at least two and one half (2.5) times their peak operating voltage.

3.2.2.3 The continuous current rating of all power semiconductors shall be at least two (2) times their expected RMS operating current

3.2.2.4 All semiconductor switching devices shall have external transient suppression circuitry. These devices shall protect against high di/dt stress and dv/dt breakover. They may include, but not be limited to, RC snubber networks, symmetrical avalanche suppression devices, or metal oxide selenium surge suppressors. Appropriate overvoltage limiting devices shall be placed at the AC inputs and outputs. In RC snubber network designs, the resistors shall be non-inductive, and the capacitors shall be of extended foil construction and made for commutation service.

3.2.2.8 The cycloconverter shall be capable of operating up to a frequency of 4 Hz (3 db full current bandwidth). No spurious or abnormal waveform distortion should exist. This system shall not exhibit oscillatory behavior. Its overall dynamic current tracking accuracy shall be =< +/- 0.1% of maximum.

3.2.2.9 Inductors shall be used in the output leads to smooth the output ripple to the induction motor rotor windings. The current ripple is defined in the specification data sheet section 20.5.

3.2.3 Sensors

The power regulating system shall include the following sensors or transducers as a minimum. These components or systems shall be commercially available, whenever possible, and shall meet or exceed the requirements of this specification.

3.2.3.1 A three phase power (MW) transducer for measuring real power which shall be used for feedback and shall be displayed on Contractor’s supplied panel meters. An isolated buffered short circuit protected analog output shall be available on a BNC connector for BNL use. The measuring accuracy shall be +/- 1% over the frequency range of from zero to 100 hertz. The scale shall be 10 volts equals 10 megawatts.

This shall include all necessary PTs, CTs, and associated electronics.

3.2.3.2 A three phase VAR transducer for measurement and regulation of the motors reactive power. The MVAR output shall be displayed on a Contractor supplied panel meter. The accuracy shall be +/- 1 % over the frequency range of from zero to 100 Hertz. The scale shall be 10 volts equals 1 MVAR. This shall include all necessary CTs and associated electronics. The VARs drawn should be held close to zero.

3.2.3.3 Three current transformers (CT’s) for measurement of the rotor currents at slip frequency and displaying these currents on Contractor supplied panel meters. Accuracy class 0.3 type C. These shall provide overcurrent protection to type CO overcurrent relays. These signals shall be sent to The scale shall be +/- 10 volts equals +/- 2000 amperes.

3.2.3.4 Three potential transformers for measuring rotor voltages. These devices shall have an accuracy of +/- 0.1% and flat response from 0 Hz to 1 kHz. DCPTs shall be used. These signals shall be available doc number Page 11 of 29 on isolated, buffered, short circuit protected BNC connectors for BNL use. The scale shall be +/- 10 volts equal +/- 250 volts.

3.2.3.5 The Contractor shall provide a set of three phase overvoltage protection devices at the output of the cycloconverter. Presently this is being done with Selenium Rectifiers. Selenium Rectifiers are preferred but the Contractor may propose alternative solution in their proposal. These protective devices shall limit the voltage to a safe value (<700 volts) and provide 24 volt alarm and trip contacts /signals when actuated.

The trip settings on these devices shall be adjustable from 50% to 110 % of maximum voltage. Firing of these devices shall engage the liquid rheostat and trip the cycloconverter off. Contacts shall be provided to trip the old cycloconverter off as well. It is BNL intention to keep the old cycloconverter as a working backup for the new equipment.

3.2.3.6 The Contractor shall supply a ground fault protection interlock for the rotor neutral adjustable from 0 to 10 amperes.

3.2.3.7 The Contractor shall provide a current unbalance sensing device for the neutral conductor. The sensor shall be a DCCT with a maximum rating of 500 amperes. This signals shall be available on an isolated, buffered, short circuit protected BNC connectors for BNL use. The scale shall be +/- 10 volts equal +/- 250 amps.

The Local and remote monitoring shall be provided.

3.2.3.8 Electronic speed transducer to determine shaft speed, slip and shaft alignment. There shall be a local display of both speed and slip. These signals shall be available on isolated, buffered, short circuit protected BNC connectors for BNL use. The scale shall be +/- 10 volts equals +/- 4% slip and + 10 volts equals 1250 rpm.

These signals will be required for the Contractor’s controller to correctly synthesis the appropriate rotor currents. The Contractor shall supply a hermetically sealed optical shaft encoder to be mounted on the motor shaft. The output of this encoder shall be used to determine shaft speed, phase, and slip. The mechanical design of this encoder shall be matched to the generator output shaft dimensions so that no modification to the shaft is required for installation.

3.2.3.9 Three current transformers for the measurement of stator currents. The stator currents shall be displayed on Contractors supplied panel meters. These signals shall be available on isolated, buffered, short circuit protected BNC connectors for BNL use. The scale shall be +/- 10 volts equal +/- 250 volts.

3.2.3.10 Frequency measurement devices used to calculate real time slip measurement by comparing line frequency with the optical shaft encoder. This device shall also provide the information necessary to synchronize the injected rotor currents with the naturally occurring rotor currents.

3.2.3.11 The existing transformer shall not be used for the new cycloconverter. It is BNL’s intent to keep the old cycloconverter as a backup for the new cycloconverter. It is highly preferred to use a new transformer for the new cycloconverter. The existing transformer specifications appear in specification data sheet for reference only.

3.2.3.12 The Contractor shall supply a full panel mimic panel showing a schematic representation of the cycloconverter, liquid rheostat, switches, and associated meters similar to the existing system. A picture of the existing panel is shown in appendix E for reference only.

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4.0 Feedback Loops

This section outlines required feedback control loops which shall be integrated into the Contractor supplied regulator. The requirements for the loops shall be met by standard, analog, solid state components packaged in modular form utilizing Eurocard packaging format or approved equal. The Contractor shall propose standard, commercial units utilized in previous applications but tailored to match the BNL requirements for gain, bandwidth, and compensation. A conceptional diagram of such a scheme is shown for reference only in appendix B.

4.1 Current Feedback Loop

This loop shall regulate on the three sensed cycloconverter A.C. output currents (rotor currents) by comparing them to the three desired currents as developed by the slip calculation circuits. The output of the circuit shall drive the cycloconverter’s triggers to hold the stator currents at the desired values. This loop shall have fast response and shall regulate the current to the value given in the specification data sheet.

4.2 Power Regulating Loop

This loop shall hold the total 3 phase input power of the motor stator on any AGS cycle constant and keep the power factor to unity by ensuring the rotor currents are in phase with the stator applied voltages. The feedback signals that feed into the regulator are derived from the actual real power and from the actual reactive power measurements. These are compared to the real power reference P* and the desired reactive power Q*, which should be held as close to zero as possible. The P* reference will be supplied by BNL and shall be scaled to 1 MW/volt. The loop shall have adequate gain and bandwidth to maintain power variations within an AGS cycle to the value listed in the specification data sheet. The phase margin shall be at least 60 degrees electrical to assure stability under all conditions.

As part of the power regulator the Contractor shall design all necessary circuitry that synthesizes and synchronizes the three rotor current reference waveforms at slip frequency. The inputs to this circuitry shall be the power reference signal P*, the line frequency, the motor speed (or slip), shaft position and the actual P and Q motor measurements.

4.3 Speed Regulation

There shall be a local switch which changes the regulator from regulating power to regulating speed. In the speed mode a local potentiometer set the desires speed from shall be used to set a reference level which can set a desired speed from 1152 to 1248 rpm. When in the speed regulation mode the input motor power is no longer regulated and is allowed to vary as required by the load on the machine. This mode is to be used for testing the system only and will not be used in operations.

4.4 Monitoring

All critical points in the circuitry of the current and power regulating loops shall be available for troubleshooting and monitoring by BNL use. Test points connected to high power points shall be isolated, buffered, and short circuit protected for BNL use.

5.0 Protection Devices and Circuitry.

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Each of the interlocks described in this section shall provide an external, isolated contact for use by BNL.

The contact shall be capable of 24-volt DC operations. Provisions for communication between Contractor and BNL PLCs may not require buffering and will be finalized at the PDR. Most interlocks should initiate switching the motor from cycloconverter control to the liquid rheostat control. Which interlocks do this will be finalized at the FDR.

5.1 A complete control and protection system shall be provided. A Siemens PLC or approved equal shall be supplied by the Contractor to monitor all cycloconverter interlocks and statuses and be capable of communicating with the existing BNL PLC system. All faults and statuses shall also be locally displayed.

All control signals shall be actuated locally via push buttons as well as remotely via the PLC. A remote/local switch shall be provided. All controls and status information shall be at a level of 24 volts D.C.

5.2 The existing relay controls for the motor operate from a 130 Vdc uninterruptible battery system.

Most of the interfaces from the cycloconverter to the existing equipment will be done via the Contractor’s PLC and the BNL PLC. Any direct interface to the existing equipment would be at the 130 Vdc level.

5.3 The cycloconverter shall have timed overcurrent protection via CO type relays. These shall be applied on both the AC input to the cycloconverter and to the rotor current outputs of the cycloconverter.

5.4 All power semiconductor heat sinks shall have an overtemperature protection scheme such as thermostat type switches mounted close to the semiconductor device which shall be set to trip before the device reaches its maximum allowable junction temperature of 100 degrees C.

5.5 There shall be overspeed protection circuits which automatically reduce the stator input power when its setpoint is exceeded. This setpoint shall be adjustable from -2% to – 3% slip.

5.6 There shall be an overspeed interlock which switches the system back to the liquid rheostat when its set point is exceeded. This shall be adjustable from -1 % to -4% slip.

5.7 There shall be an overpower (P real) interlock which switches the system back to the liquid rheostat when its setpoint is exceeded. It shall be adjustable from 1 to 10 megawatts.

5.8 There shall be an overpower (Q, reactive) interlock which switches the system back to the liquid rheostat when its setpoint is exceeded. It shall be adjustable from zero to 1 megavar.

5.9 If water cooling is used there shall be flow switches on all return paths and differential pressure interlocks between supply and return manifolds.

5.10 There shall be an adjustable rotor neutral current interlock which shall switch the system back to the liquid rheostat when tripped. The detector shall have an adjustable range of from zero to 100 amperes.

5.11 There shall be a rotor neutral ground detection circuit. This shall switch the system back to the liquid rheostat when ground current is detected. The detector shall have an adjustable range of from zero to 10 amperes.

5.12 There shall be a maximum slip permissive to turn the cycloconverter on. If the maximum slip value is not reached the cycloconverter shall not be permitted to turn on. It shall be adjustable from a slip of 3% to 1%.

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5.13 All fuses and auxiliary power supply circuit breakers shall be monitored and annunciated.

5.14 Forced air cooling paths or ducts shall be monitored by thermostat type flow sensors

5.15 All cubicles shall have ambient over temperature warning indicators remotely annunciated.

5.16 All doors which prevent access to exposed voltages greater than 50 volts shall have provisions for applying a captive key or other suitable locking devices.

5.17 All cabinet doors which prevent access to exposed voltages greater than 50 volts shall have door interlock switches.

5.18 The protection devices and circuits shall be properly isolated from the main power circuitry. All interlock status and alarm information shall be indicated and displayed on a local alarm status panel supplied by the Contractor and sent via a Contractor supplied Siemens PLC or approved equal to a BNL supplied

PLC.

5.19 The exact number of status readbacks and alarms required to adequately interface the cycloconverter to BNL’s PLC cannot be finalized until the Contractor’s design is complete. This will be done at the final design review. For the purposes of determining the cost of this interface the Contractor shall plan to provide circuitry for at least 32 I/O ports.

5.20 All interlocks shall be clearly annunciated. The following is a list of some of the interlocks which shall be required. This list will be finalized at the Final Design review:

5.20.1 Incoming Line A.C. Overvoltage

5.20.2 Incoming line A.C. Overcurrent

5.20.3 Incoming Phase Imbalance

5.20.4 Transformer Secondary Overvoltage

5.20.5 Transformer Secondary Overcurrent

5.20.6 Transformer Overtemperature

5.20.7 Semiconductor Overtemperature, including location

5.20.8 Maximum slip permissive

5.20.6 Under speed interlock

5.20.9 Over speed interlock

5.20.10 Over speed limit

5.20.11 Overpower (real)

5.20.12 Overpower (reactive)

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5.20.13 Rotor neutral overcurrent

5.20.14 Rotor ground current

5.20.15 Rotor current imbalance

5.20.16 Rotor phase overcurrent

5.20.17 Rotor phase over voltage

5.20.18 Fault in Shaft encoder

5.20.19 Incorrect Power Reference

5.20.20 Regulating mode: Power/Speed

5.20.21 Cubicle overtemperature

5.20.22 Air flow

5.20.23 Water flow

5.20.24 Water differential pressure

5.20.25 Blown fuse indicator and location

5.20.26 Five external faults from the existing system which will inhibit or trip the cycloconverter. These shall be named at the FDR.

5.20.27 Door interlocks

5.21 The interlock circuitry as well as the buffering/isolating scheme supplied by the Contractor in the Contractor supplied PLC shall be approved by the Brookhaven Cognizant Engineer prior to the start of fabrication.

6.0 Controls

The requirements for handoff between the liquid rheostat and the cycloconverter must be specified by the Contractor. At no time is the motor rotor to be open circuited during this process.

6.1 The cycloconverter power supply shall have sufficient controls, indicators and monitors for complete control of the system in both local and remote mode. All indicators shall signify true operations, not just control switch operation.

6.2 Control circuits shall be designed in a failsafe manner so that loss of power does not result in a hazardous operating condition. Protective interlocks shall be self-latching and the cycloconverter controls shall be designed so that reactivation of interlock circuits (i.e. completing the circuit) will not result in an automatic restoration of power to the equipment. The new controls must interface with the existing Motor doc number Page 16 of 29

Generator control system. For example, turning on/off the cycloconverter must be carefully coordinated with turning on/off the liquid rheostat.

6.3 The cycloconverter control functions shall include:

6.3.1 Auxiliaries OFF-All control power is de-energized using a normally closed push button.

6.3.2 STANDBY-energize all low-level controls, interlocks, and regulating circuits. When a STANDBY command is issued, a RESET pulse shall be generated in the cycloconverter which shall RESET all latched fault which have cleared. A normally open push button shall be used for this function.

6.3.3 FAULT- Indicates a fault is present.

6.3.4 If a fault is present the cycloconverter shall remain in or go to the FAULT state and a master fault indication shall annunciate. If issuing a STANDBY command and hence a RESET command clears the fault, the master fault indication shall go off and the cycloconverter shall go to the STANDBY state. The master fault indication shall be initiated when any subsystem indicates a fault.

6.3.5 ON-the ON command energizes the cycloconverter’ s main contactor. The ON command shall only be acted upon if the power supply is in the STANDBY mode and therefore no faults are indicated. This command shall also operate the circuit breakers which switch from the liquid rheostat to the cycloconverter (19R,19S,19N,52R)

6.3.6 Auxiliary contacts which indicate all commands and command statuses shall be provided for BNL use.

6.3.7 All status lines, command lines and readbacks shall interface to the BNL control system via the Contractor supplies PLC. The connectors and pin designations shall be approved by BNL at the time of the Final Design Review.

7.0 Test Points

7.1 The system shall have a suitable number of signal monitoring or test points (both analog and digital) to facilitate trouble shooting, repair, general diagnostics, and operational monitoring. All test points shall be fully buffered and isolated and brought to front panel female jacks, or BNC connectors.

7.2 The exact number of monitoring points required is a function of the Contractor’s design and will be finalized at the Design review. It is expected that a large number of test points will be necessary and that much consideration shall be given to ease of repair and troubleshooting throughout the system design.

7.3 The following is a list of some of the test points which will be required:

7.3.1 Stator Power (real)

7.3.2 Power error (real)

7.3.3 Stator Power (reactive)

7.3.4 Slip

7.3.5 Rotor Current (each phase)

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7.3.6 Rotor Current reference (each phase)

7.3.7 Rotor Current error (each phase)

7.3.8 Rotor Voltage (each phase) pre-choke and post choke

7.3.9 Frequency output from Shaft Encoder

7.3.10 Power Error signal and current error signal

7.3.11 Power reference signal, current reference signal, speed reference signal

7.3.12 Rotor neutral current

7.3.13 All modular DC power supply statuses

7.3.14 Firing pulses to semiconductor power switches.

7.3.15 Pulse inhibit signals and enable signals.

8.0 Instrumentation

8.1 The system shall have sufficient local, analog meters or appropriate displays to facilities operations, troubleshooting, and repair. The exact number of meters or displays required is dependent on the Contractor’s design and will be finalized at the design review.

8.2 The following is a list of some of the meters/displays that will be required:

8.2.1 Stator Power (real)

8.2.2 Stator Power (reactive)

8.2.3 Stator Current (each phase)

8.2.4 Rotor Voltage (each phase)

8.2.5 Rotor Current imbalance

8.2.6 Incoming AC Voltage (each phase)

8.2.7 Incoming line Current (each phase)

8.2.8 Stator Current reference

8.2.9 Slip

8.2.10 Speed

8.2.11 Rotor Current Reference

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9.0 Electrical Requirements

The specified power control system shall meet the general electrical specifications that are given in the following section.

9.1 Separate 460 Vac, high current input and output compartments, as well as a separate low voltage or control compartment, shall be provided in all units where applicable. All cubicles which have voltages greater than 120 Vac shall be lockable with captive keys such as Kirk Locks. Any voltage greater than 50 volts in a low voltage control cabinet shall be covered or barriered so that they cannot be accidentally touched.

9.2 Any electrical cable used as a power feeder or jumper shall be copper and of sufficient ratings and cross section that the cable shall not experience a temperature rise of greater than 30 degrees C at maximum current load.

9.3 All low-level control wiring shall be a type AWM appliance wire, 600 volts, 105-degree C, stranded copper conductor or approved equal. All wires shall be labeled for circuit identification at all termination points.

9.4 All cable insulation used in this system shall be of a self-extinguishing, low flame propagation, low smoke type. All cables shall be listed by a Nationally Recognized Test Laboratory. The Contractor shall include in his proposal a list of the insulating materials which will be used.

9.5 The frames of all cabinets shall have a ground pad which shall be welded to the main frame and equipped with 3/8 inch tapped holes for external ground connections.

9.6 Each phase of the AC input terminals shall be sized for at least 150% of rated current. The AC terminals shall be phased A-B-C, from left to right when facing the AC compartment door and shall be clearly labeled.

9.7 Verisafe Voltage Monitor

The Contractor shall provide an absence of voltage tester mounted to the power supply AC input terminals.

The Panduit VS-AVT-C08-L10 model shall be used or BSA approved equivalent. The user interface portion of the device shall be mounted on the front of the power supply for easy access.

10.0 Mechanical Considerations

10.1 The equipment shall be constructed in all metal cabinets which shall be in accordance with NEMA standards for Indoor Power Switch gear.

10.2 The equipment shall be partitioned into compartments. The purpose of these compartments is to ensure that access to electrically dangerous potentials can be restricted and prevented through lock arrangements.

10.3 Controls shall be housed in Eurocard type crates with room for BNL Interface circuitry.

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10.4 Provisions shall be made for lifting the equipment by overhead crane (e.g. Lifting eyes) and forklift (e.g. Channels or I-beams). Such requirements will be finalized at the design review. The frames shall be made sufficiently ridged so that frequent lifting and relocation shall not cause deformation or door misalignment.

10.6 Internal access to the equipment for servicing shall be through hinged doors. All doors and access panels to high power equipment shall have interlocks that, upon opening, switch off the power and discharge all stored energy within the enclosure. These switches shall be of the cheatable type but must reset when the doors are closed.

10.7 All bolted busbar, fuse, and rectifier joints shall use Belleville washers, flat steel washers, lock nuts and a joint compound approved by BNL. All bolts, washers and nuts shall be stainless steel.

10.8 When water cooling is used, the units shall be designed to operate with a maximum inlet water temperature of 40 degrees C, the maximum differential supply pressure shall be 50 psi. The input air temperature will be between 5 degrees C and 40 degrees C. The units shall operate reliably in a 99% humidity environment.

10.9 All bolts in blind locations shall have captive hardware.

10.10 All air filters shall be mounted on the outside of the units and be of a size and type approved by

BNL.

10.11 The accessories, materials and supplies used on this equipment shall be of the highest quality or specification grade whenever possible. The Contractor shall list in his proposal the manufacturer of fuses, relays, receptacles, terminal strips, wire hardware, etc. Auxiliary relays shall be enclosed in dustproof cases and mounted in the module control compartment.

10.12 The finish of the cabinets shall consist of degreasing of the unit followed by a coat of rustproof paint and two coats of synthetic resin enamel, color “light blue”. This shall be finalized at the design review.

11 Marking and Serialization

11.1 The Contractor shall provide and affix a stainless-steel name plate on each unit that shall include the following information:

11.1.1 Manufacturers name and address

11.1.2 Type and serial number

11.1.3 Date of manufacture

11.1.4 Input Voltage and Current rating

11.1.5 Output Voltage and Current rating

11.1.6 Cooling requirements CFM_____ GPM_____

11.1.7 Total weight

11.1.8 BNL Specification Number.

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12. Acceptance Testing (factory)

12.1 The cognizant BNL engineer and or his representative shall have access to the Contractor’s facility.

He shall witness all testing unless such rights are waived in writing on a test-by-test basis. Copies of all certified test data shall be supplied and included in the equipment’s manual

12.2 The Contractor shall inform BNL of upcoming acceptance tests as soon as they are known but no later than 14 days before testing.

12.3 The factory tests shall include but not be limited to the following. The Contractor shall specify additional factory testing in his proposal:

12.3.1 Check out and testing of all controls (local and remote), interlocks, and protective circuitry.

12.3.2 The power circuits shall be operated continuously under a load and cycle acceptable to BNL for a period of 24 hours. The test shall be at or near full power and driven by a sinusoidal control function. Short periods of downtime to make measurements or adjustments will be accepted but the total of all such downtime shall not exceed one hour.

12.3.3 The full power bandwidth and response time of the Contractor supplied system shall be measured.

12.3.4 The response of the current and power regulator sections shall be measured,

12.3.5 The TCHD of the output shall be measured.

12.3.6 The time delay and jitter of the Contractor’s triggering circuitry shall be measured

12.3.7 The blanking time shall be measured.

12.3.8 The accuracy and response of the speed monitoring equipment shall be tested.

12.3.9 The accuracy and response of the reactive and real power measurement equipment shall be measured.

12.3.10 The accuracy of the slip measurement, sinewave synthesizer, and synchronization circuitry shall be measured.

12.3.11 High Potential Tests

These tests are to be conducted for a minimum of one (1) minute. Actual leakage currents are to be monitored and recorded.

12.3.11.1 The blocked rotor voltage of the motor is 4450 Volts. All equipment connected to the motor rotor shall be hipotted to 13,000 Volts DC. This shall include CTs, PTs, inductors, cabling, semiconductors, snubbers, and protection components.

12.3.11.2 The input stator voltage of the motor is 13.8 kV. All equipment which is connected to the motor stator shall be hipotted to 35 kV DC. This shall include CTs, PTs, and protection components.

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12.3.11.3 All control circuity shall pass a hipot test of 800 VDC.

12.3.11.4 During the input and output hipot testing, all control and interlock circuitry shall be grounded.

12.3.12 Operational Tests

12.3.12.1 Cooling tests: Water and air flow measurements and static water pressure tests.

12.3.12.2 Static water tests shall be performed at 250 psi for 30 minutes.

15 Substitutions:

This specification may describe certain special materials, processes and products which will be required unless equal construction is specifically approved in writing by the BNL cognizant engineer. Should the Contractor propose to furnish other “equal” materials, processes, or products, either in substitution for or as an alternate to those specified, he shall state so in his proposal and submit full details. The cognizant BNL engineer’s decision as to the equality of any material, process, or product to those specified shall be final, but approval by the cognizant engineer shall not relieve the Contractor from his responsibility concerning such work or affect the guarantee covering all parts of the work.

16 Preparation for Delivery

All units and parts of this equipment shall be properly packaged and delivered in undamaged conditions to BNL. All water circuits shall be blown free of water prior to packaging to prevent damage during shipping or storage under freezing conditions.

17.0 Smoothing Inductor Requirements if required:

17.1 Insulation………………………………………………………..Class H

17.2 Insulation Voltage ………………………………………………10 kVdc

17.3 Consistency of Inductance with frequency………………………+/- 5%

17.4 Consistency of Inductance with current…………………………+/- 5%

17.5 Cooling…………………………………………………………..Air

17.6 Windings…………………………………………………………Copper

18.0 Existing Transformer Data

18.1 Primary Voltage…………………………………………………13.8 kV

18.2 Secondary Voltage………………………………………………3 x 202 V

18.3 Taps on Primary…………………………………………………3 x 135

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18.4 Rated Power……………………………………………………..3 x 540 kVA

18.5 Winding arrangement ……………………………………………Three-tier

18.6 Impedance………………………………………………………..6 % per system

18.7 No-load losses……………………………………………………3000 W

18.8 Short Circuit losses……………………………………………….23,000 W

19.0 Cycloconverter Requirements

19.1 Input Line Voltage to transformer..........................13.8 kV, 3 phase, 60 Hz

19.2 Voltage Input to present cycloconverter…......…..202 V 3 phase (for +/- 4% slip)

19.3 Current Output max………………………………1800 A

19.4 Maximum output voltage present cycloconverter……..+/- 270 V

19.5 Normal phase voltage at 1.5% slip……………….51 V

19.6 Maximum slip frequency………………………+/- 2.4 Hz

19.7 Harmonic Content of output current……………< 1%

19.8 Maximum Junction Temperature Power Semiconductors..........100 degrees C

19.9 The Contractor shall supply real and reactive power transducers and current transformers to measure the total power (stator plus rotor) and provide a rotor current feedback signal as required.

19.10 The Contractor shall supply all equipment needed to synthesize the correct rotor current reference signals given the BNL power reference. BNL shall be responsible for mounting the various transducers on the existing equipment, but the Contractor shall work closely with BNL to supply devices which are compatible, both electrically and mechanically, with the existing system.

20.0 System Specification Data Sheet

20.1 Range of controllable slip………………………+/- 4%

20.2 Power Regulation……………………………….+/- 0.25%

20.3 Speed Regulation. Settable................................+/- 2% of synchronous speed

20.3 Power Factor Regulation (lag)…………………1 to 0.98

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20.4 Rotor current regulation……………………….+/-0.1%

20.5 Maximum ripple current……………………..+/- 0.1%

20.6 Speed of regulator response (10%-90%)……..50 ms

20.7 Rotor total current harmonic distortion………< 1%

20.8 Frequency regulation Rotor……………….,…<+/- 0.1%

20.9 Slip Measurement…………………………….<+/- 0.1%

20.10 Machine friction and windage losses………..1.2 MW

20.11 Input Real Power Control……………………1 to 9 MW

21.0 Induction Motor Data

21.1 Output Power……………………………………9 MW

21.2 Stator Voltage……………………………………13.8 kV

21.3 Stator Current……………………………………410 A

21.4 Frequency……………………………………….60 Hz

21.5 Power Factor……………………………………0.95

21.6 Service speed…………………………………..1200 rpm +/- 4%

21.7 Stator connection……………………………..Wye with neutral

21.8 Stator terminals ………………………………6

21.9 Blocked Rotor Voltage………………………..4450 V

21.10 Rotor Current………………………………….1600 A

21.11 Rotor winding resistance to neutral……………5.6 mohms

21.12 Rotor Connection……………………………..Wye with Neutral

21.13 Number of slip rings…………………………..4

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Appendix Index

Appendix A: It is BNL’s intent to keep the existing cycloconverter as a spare unit for the new cycloconverter. It is BNL’s intention to be able to switch the incoming 13.8 kV line between the two systems. The best technical solution is to have a new dedicated transformer for the new cycloconverter and reuse the existing switchgear. The sketch in appendix A for reference only.

Appendix B: This drawing presents a generalized view of the power regulator, again for reference only.

Appendix C: This figure shows the magnet current and voltage for a 6 MW average load with a repetition rate of 4.2 seconds. This is a typical cycle but is only one of a wide range of cycles.

It is presented for reference only.

Appendix D: This figure shows the rotational speed and the slip or a 6 MW average load with a repetition rate of 4.2 seconds. This is a typical cycle but is only one of a wide range of cycles.

It is presented for reference only.

Appendix E: This is a picture of the existing mimic control panel. A similar panel is to be fabricated and installed into the new cycloconverter by the Contractor.

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Appendix A:

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Appendix B doc number Page 27 of 29

Appendix C Magnet Current in Amps verse Time in seconds for a 6 MW average load

Magnet Voltage in Volts verse Time in seconds for a 6 MW average load doc number Page 28 of 29

Appendix D

Rotational Speed in Rad/sec verses Time in seconds for a 6 MW average load

Percent Slip verses Time in seconds for a 6 MW average Load doc number Page 29 of 29

Appendix E: