SLAC Accelerators Power Electronic System Operation for Reliability F. Rafael 04/13/2011

SLAC Accelerators Power Electronic System Operation for Reliability Agenda Overview PCD Organization Tools Reliability metrics and numbers Accelerator Improvement Programs Design for reliability Conclusion SLAC Accelerators Power Electronic System Operation for Reliability Page 2

SLAC Accelerators Power Electronic System Operation for Reliability Overview PCD Sustaining Engineering SSRL (SPEAR3) LCLS (1/3 LINAC) NLCTA FACET (2/3 LINAC) SLAC Accelerators Power Electronic System Operation for Reliability Page 3

SLAC Accelerators Power Electronic System Operation for Reliability SLAC Organization SLAC is now a multipurpose laboratory for astrophysics, photon science, accelerator and particle physics research. SLAC Accelerators Power Electronic System Operation for Reliability Page 4

Service Level Agreement (SLA) Core Teams and PCD-SE Machine Value Comments Perform Period FY One Year Scope Equipment coverage Coverage Availability >99% Critical Electrical Equipment Contact Personnel Syst. Managers Includes Escalation Policy Budget FTE Power Eng. Power Tech Eng. Service M&S $k SLAC Accelerators Power Electronic System Operation for Reliability Page 5

Power Conversion Department - PCD SE SLAC Accelerators Power Electronic System Operation for Reliability Page 6

Power Conversion Department - PCD Work Planning & Control Plan the job right or don't do it! Work Planning and Control (WPC) is a standardized process used to understand the scope of work, identify qualified workers, evaluate & control hazards, communicate hazards & controls to workers, authorize, coordinate & release work and perform it within established controls. SLAC Accelerators Power Electronic System Operation for Reliability Page 7

Power Conversion Department - PCD TOOLS: PEM Work Flow 24/7 coverage SLAC Accelerators Power Electronic System Operation for Reliability Page 8

Power Conversion Department - PCD Tools: CATER SLAC Accelerators Power Electronic System Operation for Reliability Page 9

Power Conversion Department - PCD Tools: E-LOG PEM SLAC Accelerators Power Electronic System Operation for Reliability Page 10

Power Conversion Department - PCD Tools: Documentation – SODA* SLAC Accelerators Power Electronic System Operation for Reliability Page 11

Power Conversion Department - PCD Tools: Documentation - CAPTAR SLAC Accelerators Power Electronic System Operation for Reliability Page 12

Power Conversion Department - PCD Tools: Documentation - Inventory SLAC Accelerators Power Electronic System Operation for Reliability Page 13

Power Conversion Department - PCD TOOLS: EEIP SLAC – Electrical Equipment Inspection Program – EEIP Primary deployed for safety, has demonstrated improvement in reliability and used as part test acceptance and QA. Based on UL – 508A – Industrial Control Panels UL – 61010A-1 Electrical Equipment for Lab. Use http://www-group.slac.stanford.edu/essg/eeip/program.htm SLAC Accelerators Power Electronic System Operation for Reliability Page 14

Electrical Equipment Inspection Program- EEIP SLAC Accelerators Power Electronic System Operation for Reliability Page 15

Electrical Equipment Inspection Program- EEIP SLAC Accelerators Power Electronic System Operation for Reliability Page 16

Electrical Equipment Inspection Program- EEIP bonding conductor Table 15.1 of UL 508A Spacing Table 10.1 and Table 10.2 of UL 508A SLAC Accelerators Power Electronic System Operation for Reliability Page 17

Electrical Equipment Inspection Program- EEIP Poor workmanship: UL508A - 29.3.6 Wiring Methods: no loose strands protruding from the connection. Code Violation: NEC2008 - Section 110.14(A): Terminals for more than one conductor … shall be so identified SLAC Accelerators Power Electronic System Operation for Reliability Page 18

SLAC Accelerators Power Electronic System Operation for Reliability Reliability Metrics Power Conversion Department Numbers 2010 – 2011 Run LCLS SPEAR3 MTTF 84.1 (Hrs) 588 (Hrs) MTTR 0.64 (Hr) 1.45 (Hr) Availability 99.24% 99.75% Details from LCLS run was covered Monday presentation SLAC Accelerators Power Electronic System Operation for Reliability Page 19

Reliability Metrics – SPEAR3 Breakdown per System SLAC Accelerators Power Electronic System Operation for Reliability Page 20

SLAC Accelerators Power Electronic System Operation for Reliability Reliability Metrics SLAC Accelerators Power Electronic System Operation for Reliability Page 21

SLAC Accelerators Power Electronic System Operation for Reliability Reliability Metrics SLAC Accelerators Power Electronic System Operation for Reliability Page 22

Accelerator Improvements Program – AI’s LCLS Modulator failures current account for 66% of the power electronics total SLAC Accelerators Power Electronic System Operation for Reliability Page 23

Accelerator Improvements Program – AI’s 1/3 of LINAC ($2 MI) 10 Sectors 8 Modulators per Sector Modernization Cabinet 1 AC input IOC’s Interlocks Cabinet 2 and 3 PFN Switch (thyratron) Successful implementation of both upgrade projects along the length of LCLS is expected to reduce modulator failures by 60%. SLAC Accelerators Power Electronic System Operation for Reliability Page 24

Design for Reliability Paul Bellomo and Dave MacNair SLAC National Accelerator Laboratory ARW Vancouver, Canada January 26-30, 2009 Non-redundant - PEP II, SPEAR 3, LCLS (1994 – 2006) Power supply quantity is hundreds, not thousands Power supply availability budget is modest 98% Non-redundant supplies satisfied availability budget Redundant power systems not readily available from industry Redundant systems would not fit within cost and schedule constraints Redundant - KEK ATF 2 (2006 – 2008) Mock-up of ILC Final Focus accelerator Magnet power supplies ILC-like SLAC Accelerators Power Electronic System Operation for Reliability Page 25

Design for Reliability KEK ATF 2 Approach By P. Bellomo & D. MacNair SLAC Accelerators Power Electronic System Operation for Reliability Page 26

Design for Reliability Goals All components N+1 modular and redundant Power module hot-swappable Unipolar or bipolar output from a single unipolar bulk voltage source Imbedded controller with digital current regulation Capable of driving superconducting magnets High bandwidth for use in BBA or closed orbit correction systems High stability and precision output current High accuracy read-backs Scalable to higher output levels Applications ILC and other future accelerators SLAC Accelerators Power Electronic System Operation for Reliability Page 27

SLAC Accelerators Power Electronic System Operation for Reliability Conclusions PCD has successfully demonstrated using Sustaining Engineering model accomplish target goals either to support users accelerator program and experimental facilities as well. The same PCD model can accommodate Accelerator Improvements Programs and new developments for futures requirements specification, targeting High Availability Systems. Last but no least… SLAC Accelerators Power Electronic System Operation for Reliability Page 28

SLAC Accelerators Power Electronic System Operation for Reliability Now available @ IKEA Thank you! SLAC Accelerators Power Electronic System Operation for Reliability Page 29