Attachment 1_Appendix 1_VPC Power Supply Technical Specification_20220822.pdf

Specification 20220822

RevO

TECHNICAL SPECIFICATION FOR A VARIABLE

PHASE CONTROLLER FOR GENERAL ATOMICS

NEUTRAL BEAM HIGH VOLTAGE POWER

SUPPLY

Specification 20220822

Sponsored by DOE Contract Number DE-AC02-09CH11466

Prepared by A. Nagy (PPPL) and C. Pawley (GA)

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Prepared by 0■,r.mW>1U.,s.nJO-oroo- Date. __ _ Alexander Nagy

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D t repare y .onxr a e __ _ Carl Pawley

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Approved by -r /JJ/.Y--�,., o.io,2022.oaJa 14�9:11-arOO' Date __ _ Marc Barsanti h 11 0,g .. 1v lignod by John o.ti., Jo n De as 0.,.,2022.0922 ,1,"4.09

Approved by -0,1w Date. __ _ John Dellas

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Michael Ford :,!.2022.09.22 a40,12 Approved by -0,4'00' Date __ _ Mike Ford l>i91t.1I,- Y;rwd byWllwm r C:MY

Approved by William p Cary :::;:�i;:�7�:.�.u, Date-----=O.=tao:20=22.09=.22-="""="-<IT::::.:;00':..._ ----

Bill Cary

Appendix 1 ii

REVISION HISTORY

Revision Date Description of Changes

A 5-22-2022 Initial Release

POINT OF CONTACT INFORMATION

PREPARED BY:

Name Position Email Phone

Alexander Nagy Deputy Head

PPPL/GA

Collaboation anagy@pppl.gov 858-705-4452

Carl Pawley D3D HV System Chief Eng pawley@fusion.gat.com 858-455-4418

APPROVED BY:

Name Position Email Phone

Alexander Nagy Deputy Head

PPPL/GA

Collaboation anagy@pppl.gov 858-705-4452

Carl Pawley

Final Test Technical Lead pawley@fusion.gat.com 858-455-4418

Marc Barsanti DIII-D Deputy Tokamak Head, Power Systems barsma@ga.com 858-455-5198

John Dellas PPPL Electrical Group Head jdellas@pppl.gov 609-243-2173

Michael Ford Associate Lab Director for Engineering mford@pppl.gov 609-243-2866

William Cary DIII-D Deputy Tokamak Head cary@fusion.gat.com 858-455-2486 mailto:pawley@fusion.gat.com mailto:pawley@fusion.gat.com iii

TABLE OF CONTENTS

Contents

1 INTRODUCTION

1.1 Scope

1.2 System Description

2 REFERENCES

3 SYSTEM REQUIREMENTS

3.1 Functional Description

3.2 Section 4 Electrical Requirements

3.2.1 Mechanical Requirements

3.2.2 Environmental Requirements

3.2.3 Interface Requirements

3.2.4 Controls

3.2.5 Monitors

3.3 Other Requirements

3.3.1 Painting

3.3.2 Nameplates and Product Marking

3.3.3 Other Markings

3.3.4 Tools

3.4 Documentation Requirements

3.4.1 Operating and Maintenance Manual

3.4.2 Spare Parts List

3.5 Testing Requirements

LIST OF FIGURES

Figure 1 Simplified Functional Schematic Showing the HV Power Supply Figure 2 Autotransformer with tap changer on near side Figure 3 Autotransformer to be replace by the new Variable Phase Controller Figure 4 Plan view of equipment and pad

LIST OF TABLES

Table 1 PLC control for monitoring of interlocks Table 2. Seismic Static Equivalent Load Cases

1-iv

ACRONYMS AND ABBREVIATIONS

Acronym/Abbreviation Description VPC Variable Phase Controller

PPPL Princeton Plasma Physics Laboratory

GA General Atomics

NIST National Institute of Standards and Technology

AT Autotransformer

NB Neutral Beam

HVPS High Voltage Power Supply

LCS Local Control System

PW Pulse Width

1 INTRODUCTION

The Neutral Beam system injects high energy neutral atoms into the DIII-D tokamak to heat the plasma and increase its density. The atoms must be neutral to go through the magnetic field lines that hold the main plasma in a toroidal “magnetic bottle”. The neutral atoms are re-ionized in the main plasma chamber and then trapped in the main plasma.

The Neutral Beam atoms start off as plasma (ions and electrons) in the NB source. This plasma is extracted from the source chamber using a set of grids, like a vacuum tube, with the accel grid being the highest voltage, 70-83kV presently. It is desirable to increase the beam energy by going to as high as 94kV but is limited by the head room on the power supply and the stability of this high voltage.

The High Voltage power supply droops when the NB is pulsed and to alleviate this droop the auto transformer primary taps, that feed into the HV transformer/rectifier, are moved to increase the charging voltage to as high as 120kV, before the pulse. A phased controller with active feedback is desired so the input can react to the HV transformer/rectifier output demand.

This system was analyzed, by PPPL Engineering in Fall 2021, see technical report 1142021 attached, and it was determined that this type of phased controller could work to eliminate the large voltage droop when the system is pulsed.

1.1 Scope

The scope of this specification includes technical details of the Variable Phase Controller (VPC) A. The design is for a 3 phase, 12.47kVAC, 400A, variable phase controller as a replacement for the tap changer to the AT/Tap system presently used to vary the input of the NB high voltage transformer.

B. This system will need to fit into the space presently taken up by the AT.

1.2 System Description

The VPC system will be used to vary the input voltage to the NB HV transformer as needed to avoid capacitor bank droop when a pulse is commenced.

Figure 1 shows a block/schematic diagram of the NB HV system. This is a basic diagram meant to show the function and context of the HV power supply; it is not intended to provide design guidance.

Figure 2 Autotransformer with tap changer on near side

12 4 27

Fuse To

1000 ft Undergro d

55 kV – 120 kV T

Tap Changer

0.7

Variable Phase Controller to replace tap changer

Figure 1 Simplified Functional Schematic Showing the HV Power Supply

Figure 3 Autotransformer to be replace by the new Variable Phase Controller

2 REFERENCES

This work shall meet applicable codes e.g. NEC, ASMI, and NFPA as required.

See PPPL Technical Report ---11142021

3 SYSTEM REQUIREMENTS

This section identifies the functions and requirements of the VPC. Sellers are encouraged to contact GA with suggestions for changes that would result in a reduction in cost, schedule, or complexity and/or an increase in reliability.

3.1 Functional Description

The VPC is used to vary the voltage on the NB accel grids from 50kV tp 100kV at the output of the HV transformer rectifier. Presently a significant droop exists at voltages above 80kV. This system needs to respond in time (<20ms) to boost the HV transformer input voltage when the rectifier cap bank fires a pulse. Functional interlocks and trips are specified below in section 3.2.

It is assumed that the VPC would reside in an oil bath, thus requiring the appropriate nitrogen blanket with associated oil level and pressure indicators.

3.2 Electrical Requirements

The UVC should provide:

FIGURE 4 Plan view of equipment and pad

A. Operations for 10s PW every 10 minutes

B. Input 3 phase 12.47 kVAC, 60Hz

C. Input 400A/phase max

D. Power 10 MW max

E. Output voltage range 3kVAC to 10kVAC12.47 kVac

F. Response time <10 ms

G. Overshoot 5%

H. Recovery Time 20ms max

I. Feedback—internal

J. Start Command---charge to capacitor bank set level 80-110 kV

K. Cap bank sag duration <10ms

L. Voltage sensor at cap bank is Ross voltage divider

Table 1 PLC control for monitoring of interlocks

Interlock Action Time Response

1 Temperature Monitor Inhibit pulses 2-3 ms

2 Input Voltage Monitor Inhibit pulses 2-3 ms

3 Input Current Monitor Inhibit pulses 2-3 ms

4 Any Fault Opens Breakers 2-3 ms

5 Phase Fault Opens Breakers 2-3 ms

6 Input Overvoltage Opens Breakers 2-3 ms

7 Input Over Current Opens Breakers 2-3 ms

8 Output deviation from command 10%

Opens Breakers 2-3 ms

9 Ground Fault Opens Breakers 2-3 ms

3.2.1 Mechanical Requirements

3.2.1.1 The VPC shall be housed in an enclosure to fit within the footprint of the AT on the concrete pad.

3.2.1.2 The concrete pad location is designed to support heavy loads ~5000lb/ft2.

3.2.1.3 Provision shall be made to install using a crane with appropriate lift points.

3.2.1.4 The VPC assembly shall be enclosed in an enclosure suitable to protect personnel from exposure to moving parts, high voltage, or other hazards.

3.2.1.5 Provision shall be made for grounding the enclosure. The design and location of the grounding connection will be mutually agreed to by both parties.

3.2.1.6 The VPC design shall be capable of withstanding vertical and lateral seismic acceleration loads without permanent deformation to any components. Concrete pad anchoring shall prevent tipping-over or shifting of the power supply. The seismic load cases are provided in Table 1. The type and location of the fasteners will be mutually agreed to by both parties.

Table 2. Seismic Static Equivalent Load Cases

Load Case SEVertical SEHorizontal 1 1.120 0.4 2 1.077 0.3 3 0.498 0.4

Forces acting on the structure during a seismic event are calculated from the above parameters as follows:

Force acting vertically down, FV(seismic)=SEVertical x mass x g Force acting horizontally, FH(seismic)=SEHorizontal x mass x g Where g=9.81 m/s2

3.2.1.7 All access panels that allow access to any hazardous component (moving parts, high voltage, etc.) shall be interlocked and require a specialized tool to remove or open e.g.

socket head, torqs head etc.

3.2.2 Environmental Requirements

3.2.2.1 The VPC shall be installed outdoors.

3.2.2.2 Ambient operating temperature shall be from 0°C to 40°C.

3.2.2.3 Ambient operating relative humidity shall be from 5% to 100%.

3.2.3 Interface Requirements

3.2.3.1 The VPC shall connect to the input/output high current bus work using bolted connections. The design and configuration will be mutually agreed upon by both parties.

3.2.3.2 Cooling water is not available.

3.2.3.3 Fans or convection are allowed.

3.2.4 Controls

The controls shall be in accordance with the list above in section 3.2 in addition to those below.

3.2.4.1 As a minimum, the power supply shall accept the following commands from an external source:

a. Vset: A 0 → +10V input signal sets the output voltage in voltage regulation mode. The input range shall scale linearly to an output of 0 → +120kV.

b. Output On: Moves the VPC from the Output Off state to the Output On state. This shall be accomplished by the presence of 24Vdc.

c. Output Off: Moves the VPC from the Output On state to the Output Off state. This shall be accomplished by the absence of 24Vdc. This signal shall take precedence over the Output On command.

d. Emergency Off – Move the VPC from either the Output On or the Output Off state to the Fault state. This shall be accomplished by the momentary absence of 24Vdc.

e. Fault Reset - Assuming no fault conditions exist, this will move the VPC from the Fault state to the Output Off state. This will be accomplished by the momentary presence of 24Vdc.

f. Interlocks - provision shall be made to monitor for an external interlock (contact closure).

Opening of the interlock shall cause the power supply to enter the Fault state.

3.2.4.2 The emergency off and interlock operation of the VPC shall not depend on software.

3.2.4.3 The opening of any interlock including the emergency off shall constitute a fault and place the power supply in the fault state.

3.2.4.4 A fault state must be cleared by the correction of the fault and the input of a reset signal.

Prior to reset, the power supply shall not be capable of being put in the Output On or Output Off state. Upon reset, the power supply will enter the output off state.

3.2.4.5 The controls shall be self-monitoring. In the event of a loss of control or communication, the VPC shall initiate a fault resulting opening of the input breaker.

3.2.5 Monitors

The VPC shall provide signals for external monitoring of critical parameters and states. As a minimum they shall include those listed below. Unless otherwise noted, binary signals shall be 24 vdc and analog signals shall be 4-20 mA preferred or 0-10Vdc. All sensors/transducers shall be calibrated and traceable to NIST or other equivalent standard. Calibration certificates shall be supplied with the equipment.

3.2.5.1 Monitoring signals shall include as a minimum:

a. Mains Power OK – 24V indication that 12.47kVolts is within acceptable limits and all phases are present.

b. Off State – 24V indication that power supply is in the off state.

c. On State - 24V indication that power supply is in the on state.

d. Fault State– 24V indication that power supply is in the fault state.

e. Interlocks Closed – 24V indication that all interlocks are closed and all faults are cleared.

f. Oil Temperature – 24V indication that oil temperature is within the acceptable range.

g. Oil Level – 24V indication that oil level is between acceptable level range,

h. Over Temperature – 24V indication for each monitored temperature (heat sink temperature for example) that temperature is within acceptable limits.

i. Fault Condition– 24V indicates that no fault condition exists. This signal shall not be dependent on software. Loss of this signal will initiate opening the input breakers.

j. Voltage – 24V indication that the output voltage is within normal limits

k. Current – 24V indication that the output current is within normal limits

l. 120/208/480V Input Power Status – 24V indication that the input power is acceptable (voltage, phases, frequency). This may be a combined signal or individual signals.

m. A diagnostic to determine an SCR/IGBT phase failure to expedite any repair.

n. Other monitors as determined by the manufacturer necessary for monitoring the status and health of the power supply.

3.3 Other Requirements

3.3.0 The design of the SCR/IGBT support and connections shall any phase to be easily removed to be tested and repaired and a spare put in to restart operations quickly from a phase control failure mode. (A design using Staubli Contacts at the bottom and the top of the SCR stage is suggested, Buyer can provide information if requested.)

3.3.1 Painting

3.3.1.1 The exterior surfaces of the VPC shall be painted using a high-quality paint or powder coating process. Painted surface shall be durable so that it can be easily cleaned without degradation to the paint.

3.3.1.2 The preferred paint color is blue, shade to be specified by GA.

3.3.2 Nameplates and Product Marking

3.3.2.1 The VPC shall have a permanent nameplate on its external surface containing the following information as a minimum:

a. Manufacturer's name and location

b. Part number

c. Serial number

d. Date of manufacture

e. Rated capacity

f. Power requirements

g. Other pertinent information

3.3.3 Other Markings

3.3.3.1 Replaceable components and wiring shall be marked with reference designations keyed to drawings and diagrams that will be used for maintenance.

3.3.3.2 Warning decals/signs shall be applied to equipment that can cause serious injury and or damage to property and personnel.

3.3.3.3 The decals and signs shall be able to withstand outdoor conditions, sun, rain, and wind.

3.3.3.4 Interfaces and connections shall be clearly identified.

3.3.4 Tools

3.3.4.1 Special installation/maintenance equipment not commercially available shall be provided by the Seller. Metric tools are not considered special tooling.

3.4 Documentation Requirements

3.4.1 Operating and Maintenance Manual

3.4.1.1 The system shall be furnished with an operating and maintenance manual prepared in accordance with good commercial practice and written in English.

3.4.1.2 Both a physical copy and an electric copy of the manuals shall be provided.

3.4.1.3 The manual shall include an overall description of the system with instructions for installation, commissioning, operation, and troubleshooting by qualified technicians and engineers. The manual shall also describe any periodic testing if required.

3.4.1.4 The manual shall incorporate a parts list, drawings, and diagrams sufficient to troubleshoot the system and to identify replacement parts and their sources.

3.4.1.5 The life expectancy of the high power electronic components shall be listed.

3.4.2 Spare Parts List

3.4.2.1 The system shall be furnished with a list of recommended spare parts. Long lead time parts shall be identified in the list.

3.5 Testing Requirements

The power supply shall be tested in accordance with the statement of work and a test plan to be jointly developed with and approved by the Buyer.

3.5 Testing Requirements