Transcript Presenting a Technical Report

FERMILAB
LINAC PROTON SOURCE MODULATORS
7/17/2015
1
Dan Wolff/Howie Pfeffer
MODULATOR SPECS
• Output Voltage:
120kV
• Output Current:
140 amps
• Output Pulse Length:
4.5 ms
• Pulse Rate:
3 Hz
• Input Voltage:
480 VAC
• Spark Energy Limit:
20 joules
• Regulation (incl. slope): 1 % (?)
• Design should minimize cost for upgrade
to 10 Hz pulse rate at 1.5 ms pulse width.
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Dan Wolff/Howie Pfeffer
POTENTIAL MODULATOR TECHNOLOGIES
• FNAL (Bouncer-type) with Updated Technology
* Higher Voltage IGBTs, New Caps, New Controls
•
SNS – High Frequency Switcher
+ Small Size
+ Being commercially produced
- As yet, unproven operational reliability
- Passive circuit on secondary to control spark energy
deserves further investigation
- HV/HF Transformer is tricky. Is it reliable?
- Pulse flattening yet to be demonstrated
• Miss-Matched PFN – Russian Idea, not demonstrated
+ No Bouncer Needed
+ Interesting, might be more reliable
- Need to build one
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7/17/2015
Dan Wolff/Howie Pfeffer
FNAL Bouncer-type 4.5 ms Modulator
“Simplified” Schematic
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Dan Wolff/Howie Pfeffer
Bouncer-type Modulator with Updated Technology
•
IGBT Switch:
– Using New Higher Voltage Devices:
50% reduction in cost and physical size
• Main Capacitor Bank:
Using New “HAZY” Self-Healing Polypropylene Capacitors
50% Reduction in Cap Cost and Physical Size
• Modulator Controls:
Using Lab G type – SM Components, fewer cable interconnects
25% reduction in parts, 50% reduction in labor
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Dan Wolff/Howie Pfeffer
Bouncer-type Modulator - New Features
• Redundant IGBT Switch Design
- Eliminating the Backup Switch: 20% reduction in cost
- BUT Requires redundancy in number of switch devices and gate controls
- Replaces Ignitrons with less expensive SCRs in crowbar circuit
- Eliminates very high current crowbars and associated noise
- Maybe a zero gains feature but better reliability
• Boost Converter Regulation
- Goal is to achieve +/- 5% control/regulation
- Allows for multiple modulators fed from one charging power supply.
• Smoothing Choke
- Series choke of sufficient size to limit AC line fluctuations to +/- 1%
(present Linac area AC lines 15Hz voltage distortion).
- If new Linac fed from dedicated 345kV transformer, above
requirement could be relaxed.
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Dan Wolff/Howie Pfeffer
4.5 ms Modulator Design Features that
minimize 1.5ms upgrade costs
•
2 parallel IGBT Switches
•
Main Cap Bank designed to separated into 3.
RMS current based on 10 Hz 1.5 ms operation
•
Bouncer Caps and Inductors designed to be separated into 3.
RMS current based on 10 Hz 1.5 ms operation
•
Charging Power Supply
Assuming boost converter regulation works, the same charging PS
could be used to power 3 of the 1.5 ms modulators.
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Dan Wolff/Howie Pfeffer
Original FERMI TESLA MODULATOR – Parts Cost
 Pulser Parts Cost
• Pulse Transformer: $108k
• Pwr Transformer:
$ 50k
• Main Cap Bank:
$ 31k
• Cabinet:
$ 15k
• Other:
•
$126k
Subtotal:
• IGBT Switch
$330k
Subtotal: $ 50k
• Modulator Controls Subtotal: $ 40k

TOTAL: $420K
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Dan Wolff/Howie Pfeffer
Original FERMI TESLA MODULATOR – Total Cost
• PULSER PARTS ESTIMATE:
• RF MODULES (Spark Detection):
•
$420k
$12k
(AWAG)
LABOR ESTIMATE:
(Total parts cost) – (Pulse Transformer)
$422k - $108k = $314k

TOTAL (1996 $’s): $735k
 TOTAL:
Inflation Since 1996 (8 yrs at 2.5%/yr) = 22%
1.22 x $735k = $900k
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Dan Wolff/Howie Pfeffer
Original Fermi TESLA Modulator
Updated Technology cost savings
•
IGBT Switch:
Using New Higher Voltage Devices and eliminating the backup switch:
• $60k savings in labor and parts
• Main Capacitor Bank:
Using New “HAZY” Self-Healing Polypropylene Capacitors
• $30k savings in labor and parts
• $5k savings in Cabinet, Reduced Service Building Size!
•
Controls Upgrade:
•
$30k Savings in parts and labor
• Total updated technology savings:
$125k
 TOTAL:
Inflation Since 1996 (8 yrs at 2.5%/yr) = 22%
1.22 x ($735k-$125k) = $745k
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Dan Wolff/Howie Pfeffer
4.5 ms Modulator Cost Estimate
• Pulse Transformer: $108k
[ x sqrt(3) ]
$190k
• Pwr Transformer:
$ 50k
[same]
$50k
• Main Cap Bank:
$ 31k
[ x1/2 x3]
$50k
• Cabinet:
$ 15k
[ x8/5 ]
$25k
[see notes]
$270k
• Other:
$126k
Subtotal:
• IGBT Switch
Subtotal: $ 50k [ x 4/10 x2]
• Modulator Controls Subtotal: $ 40k [x 5/8]

$585k
$40k
$25k
TOTAL parts: $650K
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Dan Wolff/Howie Pfeffer
4.5 ms Modulator Cost Estimate – Total Cost
• PULSER PARTS ESTIMATE:
$650k
• RF MODULES (Spark Detection):
•
$12k
(AWAG)
LABOR ESTIMATE:
(Total parts cost) – (Pulse Transformer)
$650k - $190k = $460k

TOTAL parts and labor (1996 $’s): $1122k
 TOTAL:
Inflation Since 1996 (8 yrs at 2.5%/yr) = 22%
1.22 x $1122k = $1370k
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Dan Wolff/Howie Pfeffer
ESTIMATED SIZE
!
Simple scaling, no attempt to optimize
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Dan Wolff/Howie Pfeffer
4.5 ms Modulator
Project Organization
•
Project Leader:
Howie Pfeffer
•
Magnetics:
Chris Jensen
•
Controls:
Jim Biggs (& P. Prieto)
•
Switch, Cap Bank, Bouncer, Misc.,
Leon Bartelson
and construction:
•
Computer Simulations:
Dan Wolff
• Estimated project time
Design, construction, and commissioning: 18 months
after $’s available.
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Dan Wolff/Howie Pfeffer