ILC Power Distribution
Status Presentation
Hamburg, May 2007
J. Pedersen
CERN
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May 2007
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Status: Power Distribution
• This presentation is an updated
version of the one made in Valencia
in November 2006.
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2007
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Status: Power Distribution
• Since Valencia, November 2006
the following has happened:
– The power needs of the project seems
to stabilize around 230 MVA
– The unit loads in certain areas are still
to be defined in more detail to allow
the Engineering Design to start
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2007
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Contents
•
•
•
•
•
Load schedule
Network design
The area systems
Safe power systems
Cost Reductions
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Load Schedule, User demands
• The users have analysed their load
demands and have arrived at an overall
load of around 230 MW.
• The breakdown of the load is only partially
available and the location of the load
elements is not developed. Work is needed
here to allow the detailed Engineering
Design to start
• The Need for the integration studies of
equipment to be installed in the limited
underground space should not be
forgotten!
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Load Schedule
MW
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Load Schedule
ILC top level distribution: 400 kV/36 kV VALENCIA
Services links 36 kV
500
3150
5100
11
7
5100
2750
5
26 MW
32.5 MVA
520 A
3
2750
5100
4
2
1.x
41 MW
51 MVA
816 A
32 MW
40 MVA
640 A
5100
6
32 MW
40 MVA
640 A
32 MW
40 MVA
640 A
3 x 300 mm2 Cu: 795 A
15
MW
500
10
26 MW
32.5 MVA
520 A
3 x 240 mm2 Cu: 700 A
3 x 240 mm2 Cu: 700 A
RTML 10 MW
3150
3 x 400 mm2 Cu: 915 A
Main Linac 75 MW
30 MW
3 x 400 mm2 Cu: 915 A
30 MW
30 MW
3 x 300 mm2 Cu: 795 A
Main Linac 75 MW
30 MW
Dumps 4 MW
Service tunnel
15 RTML 10 MW
MW
e+ source 20 MW
e+ source
BDS 12
MW
Beam tunnel
BDS 12 MW
5 MW
6 MVA
Cable current capacity done
for: Air, flat formation
90 C
screens bonded at both ends
e- source
15
25 MW
31 MVA
14
e- Source 5 MW
MVA ?
Damping ring 25 MW
12
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2007
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Network Design
• The retained voltage levels are (European site) :
– Grid connection: 400 kV
– Energy transport to the pits and access areas
(Distribution substations): 36 kV
– Energy distribution in the areas: 36 kV
– 3.6 kV for large motor-compressor sets (> 400
kW; cryogenics?, chillers?)
– 3.6 kV for the safe power transport
– Local distribution to the general user: 400/230 V
• Regional differences will exist. They are
considered of limited importance for the design
and the cost.
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2007
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Network Design
• The center of the network will be the
main substation, containing (European
site):
– One bay for the connection to the grid
– Four transformer bays: 400/36 kV
– Four 36 kV bus-bars, interconnected
with bus-ties, allowing operation with
one transformer failed.
• A simple lay-out of the main sub-station
is shown in fig. 1
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Network Design
• Central substation 400/36 kV
400 kV
130 MVA
130 MVA
1
36 kV
cable link
to point 1
5
36 kV
cable link
to point 5
7
36 kV
cable link
to point 7
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2007
130 MVA
3
36 kV
cable link
to point 3
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130 MVA
6
36 kV
cable link
to point 6
2
4
36 kV
cable link
to point 2
36 kV
cable link
to point 4
10
Network Design, Power Ratings
• The total power, demanded by the users
(RDR) is 230 MW
• Then the power rating of the
transformers would depend on the
power factor:
• PF = 0.80 => 288 MVA
• PF = 0.85 => 270 MVA
• PF = 0.90 => 256 MVA
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Network design
• Prudence will that the transformer rating is
selected at 110 MVA per unit minimum.
– (1770 A, well within the limit for standard 36
kV equipment: 2500 A)
• This represents a reserve of roughly 20% with
respect to the load, at cosphi = 0.85.
• It is proposed to invest in a hot spare - kept
under voltage, possibly in operation - i.e. four
units in total.
• 110 MVA units can be easily manufactured and
transported as three phase units. Road
transport is feasible
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2007
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Network design
• The main substation will have four 36
kV bus-bars. Each of the three active
transformers will feed one of them.
• The distribution substations in the
access areas will be fed from the main
sub-station by 36 kV cable links.
• The cables are laid in open loop
configuration. This gives added
operational flexibility in case of
equipment failure in the top level power
distribution.
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Network Design
• Open loop
36 kV cable links to
the central substation
Pit n
Pit n + m
RMU
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Network design
• The 36 kV cables will be run in the service
tunnel.
• They will run on cable ladders, equipped with
perforated covers. This will provide mechanical
protection.
– European version; regional differences may
exist here.
• In the central area, between pit 2 and 1, up to
8 sets of three single core cables may be
routed in the tunnel.
• Over the major part of length of the Linac it
will be 2 sets plus one, for the emergency
supply, running in the service tunnel.
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Available short circuit power
•The short circuit power with this solution will
vary from around 200 MVA on the 36 kV busbar
in the furthest pit to around 675 MVA
on the 36 kV busbar in the central substation.
•These values can be influenced by the
transformer design and the cable cross section.
•During the engineering design the voltage
drops in the system downstream in the furthest
points should be given attention.
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Network design
• The distribution substations will
comprise two 36 kV switchboards,
made up of 36 kV modular switch gear
• One for machine supply
• One for services
• Each switchboard will have voltage
monitoring
• The two switchboards will be
interconnected by a bus-tie.
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Network design
• Each feeder will be equipped with the
relevant protection equipment, able to
perform protection, measurements,
logical sequences for interlocks etc. and
oscillographic event recording.
• The next four figures show single line
diagrams of the substations of pits 2, 4
5 and 12.
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Network design
36 kV links to main substation
Machine network
36 kV busbar
Service network
e- tunnel
RF2-4
2 MVA
2 MVA
400 V
?
Chillers
1560 kVA
BDS
tunnel
6 MVA
Tunnel services,
1.0 and 1.1 to 2
400 V
Cryogenics
warm
building
Tunnel services,
2-4
2 MVA
1.25 MVA 400 V
Shaft
access
building
Y kV
Cryogenics
cold
buildings
Process water 1383.8 kW 2 MVA
8 exhaust fans each 12 kW
400 V
Subst.
auxiliaries
2 MVA
400 V
workshop
2 MVA
400 V
Cooling
and vent.
2 MVA
2 MVA
1.575
MVA
1.25
MVA
Site
access
e- source. 4 feeders/transformers,
1 feeder/transformer for RF.
Surface
Underground
Office area
Office
building
400 V
Personnel
facilities
building
BDS
Service tunnel
Pit 1.0, 1.1
Beam tunnel
Pit 4
Substation pit 2, Main Linac, e- source
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Network design
36 kV links to main substation
Machine network
RF 2-4
2 MVA
3 MVA
2 MVA
6 MVA
RF 4-6
6 MVA
1.25 MVA
Tunnel services,
2 to 4
400 V
Dehumidifiers
4x350 kW
400 V?
Chillers
2603 kVA
400 V
Cryogenics
warm
building
36 kV busbar
Service network
Y kV
Cryogenics
cold
buildings
Tunnel services,
4 to 6
Y kV
Cryogenics
cold
buildings
2 MVA
400 V
Shaft
access
building
Process water 1383.8 kW 2 MVA
8 exhaust fans each 12 kW
400 V
Subst.
auxiliaries
2 MVA
400 V
workshop
2 MVA
400 V
Cooling
and vent.
Office area
Site
access
Office
building
400 V
Personnel
facilities
building
Surface
Underground
Service tunnel
Pit 2
Pit 6
Beam tunnel
Substation pit 4, Main Linac
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Network Design
36 kV links to main substation
3 MVA
2 MVA
400 V
Dehumidifiers
4x350 kW
2 MVA
400 V?
Chillers
2603 kVA
6 MVA
400 V
Cryogenics
warm
building
36 kV busbar
Service network
Machine network
6 MVA
Y kV
Cryogenics
cold
buildings
Y kV
Cryogenics
cold
buildings
RF 5-7
RF 3-5
1.25 MVA
Tunnel services,
5 to 7
Tunnel services,
3 to 5
2 MVA
400 V
Shaft
access
building
Process water 1022.8 kW 2 MVA
4 exhaust fans each 12 kW
2 MVA
2 MVA
2 MVA
2 MVA
400 V
Subst.
auxiliaries
2 MVA
400 V
workshop
2 MVA
400 V
Cooling
and vent.
2 MVA
Office area
Site
access
e+ source, undulator. 2 feeders/transformers for
beam part, 3 feeders/transformers for service part,
Office
building
400 V
Personnel
facilities
building
Surface
Underground
Service tunnel
Pit 7
Beam tunnel
Pit 3
Substation pit 5, Main Linac, e+ source
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Network Design
36 kV
36 kV damping ring loop
2MVA
400 V
630 kVA
400 V
Process
water
361 kW,
8 x 12 kW
fans
M
2 MVA
400 V
Power
converters,
magnets?
2 MVA
400 V
Klystron power
supplies
Surface
Underground
Damping ring tunnel
Pit 13
Pit 3
Substation Pit 12, Damping ring
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Network design
• The power distribution in the tunnels will be
based on 36 kV cable links, distributing via
Ring Main Units and local distribution
transformers: 36 / 0.4 kV. The local
distribution will be 400/230 V three phase.
– European version; regional differences may
exist.
• The 400/230 V cabling will be five-wire,
including neutral and PE, except specific cases
where only three phase systems are supplied;
f. ex. power converters.
– Regional differences may exist, depending on
standards.
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Tunnel High Voltage
Main Linac 36 kV
RF supplies, transformers supplied by RF system
1 RF unit
36 m
Conventional
supplies
4 RF units
144 m
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Tunnel High Voltage
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Tunnel High Voltage
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Tunnel High Voltage
B
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Tunnel High Voltage
25 – 39 MVA
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Tunnel distribution
Lay-out of the supply for a 144 m tunnel segment
Tunnel floor.
Tunnel diameter: 4.5 m
400/230 V distribution
switchboards
Transformer 36kV/0.4 kV
Air-cooled, cast resin.
RMU
Centerline
800
1460
1550
1050
750
1050
3800
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Tunnel Distribution
An RMU in a 4.5 m tunnel
4.5 m
1050
2000
1100
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Tunnel distribution
• Auxiliary voltage
– The equipment in the tunnel will most likely
need an auxiliary voltage: 48 V D.C.
• This voltage cannot be transported
reasonably over large distances;
– Voltage drop versus cable section
• Alternative:
– Produce 48 V at every 144 m, including
batteries! Reliability, maintenance
(Approximately 170 sources.)
• To be looked into during engineering design
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Network design
• Each distribution substation will comprise a
complete 48 V supply with battery back-up
for the safety systems:
– The protection equipment of the H.V system
– Trip coils and other auxiliaries of the H.V. and
L.V. switchgear
– Emergency lighting
– Emergency stop systems
– Power network SCADA system
• The 48 V supply will have two battery
chargers, two 48 V distribution switchboards
with a bus-tie and two batteries, NiCa. These
installations shall be backed up by the diesel
gen. sets
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Tunnel distribution
• Thermal considerations
• The switchgear, transformers and cables all
dissipate heat in the tunnel.
– Typical values:
• RMU: RMU
• 400 V switchgear: 1 kW per column, rated load
• 500 kVA transformer:
– No load losses: Po = 2 kW
– Load losses: PCu = 6.5 kW
• Cables: ?
– Per 144 m module: (RMU + 8.5 + 3 + ?)kW
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Network design
• Interface to the other systems
– Where does the cost and responsibility
of the A.C. power distribution stop?
• Example, sub-distribution:
– The limit of the responsibility of the
A.C. distribution is the end of the cable
reaching a sub-distribution board
installed by another team. The
distribution internal to the subdistribution is the responsibility of the
relevant team.
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Network design
• Example, cooling skid:
– The limit of the responsibility of the A.C.
distribution is the end of the cable reaching a
cooling skid. Any distribution internal to the
skid is the responsibility of the cooling team.
• Example, cryogenic motor-compressor set:
– The limit of the responsibility of the A.C.
distribution is the end of the cable reaching the
connection points of the motor. Any
distribution internal to the compressor set is
the responsibility of the cryogenics team.
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Network Design
Shaft 5, cooling and vent.
Transformer 4-5
2.5 MVA, 36kV/0.4 kV
Sump
pumps
Towers,
chilled
water
23 kW
12 kW
6 kW
21 kW
10 x 40 A
210 kW
10 x 40 A
10 x 32 A
120 kW
10 x 16 A
60 kW
17 x 60 A
379 kW,
Vancouver version
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17 x 32 A
204 kW,
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17 x 40 A
357 kW,
17 x 16 A
102 kW,
36
Heater
10 x 100 A
Fan pump
Cooling tower pump
Cooling tower fan
Cooling tower spray pump
Cooling tower immersion heater
Cooling tower immersion heater
Cooling tower spray pump
17 x 40 A
357 kW
Cooling tower fan
Cooling tower spray pump
Cooling tower fan
Chiller
1560 kVA
Heater
Cooling tower pump
112 kW
112 kW
150 kW
150 kW
10 x 60 A
224 kW
Switchboard type 3
Cooling tower pump
Cooling tower pump
Chilled water pump, secondary loop
Chilled water pump, secondary loop
Dehumidifiers
Fan pump 17 x 100 A
680 kW
Cooling tower immersion heater
4fans, 4 x 32 A
48 kW
Cooling tower pump
350 kW
350 kW
350 kW
350 kW
Dehumidifiers
and fans
Cooling tower pump
Chilled water pump, primary loop
Chilled water pump, secondary loop
3 sump pumps
3 x 100 A
168 kW
Transformer 10-5
2.5 MVA, 36kV/0.4 kV
Process
water
Switchboard 3600 A, 400 V type 1
Tower,
process
water
Chilled
water
75 kW
75 kW
150kW
Switchboard 3600 A, 400 V type 1
Transformer 6-5
2.0 MVA 36kV / 3.6 kV
?
Main Linac
• The power distribution of the Main Linac
consists of three major systems:
– The conventional services supply
• The services will be supplied from a 36 kV cable link with
RMUs inserted every 144 m, or every 4th RF unit. A 500
kVA, 36/0.4 kV transformer and a switchboard will handle
all conventional power in a 144 m module.
– The RF supply
• Only a 36 kV cable link and the RMUs will be provided.
– The safe supply
• Based on diesel generator sets and, possibly static UPS
systems. Still to be defined in detail.
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Main Linac
• The conventional services supply
– The services will be supplied from a 36 kV
cable link with RMUs inserted every 144 m, or
every 4th RF unit. A 500 kVA, 36/0.4 kV
transformer and a switchboard will handle all
conventional power in a 144 m module.
•
•
•
•
•
•
The overall non-RF load is approximately 70 MW
Applying PF = 0.85 we get 82 MVA.
There are 157 modules of 144 m.
Per module the non-RF load is thus 520 kVA.
A 500 kVA transformer has been foreseen.
A bit of fine tuning will be needed.
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Main Linac
• Power needs of 144 m Main Linac tunnels, according to criteria
sheet
• Beam tunnel
– Cryogenic module with quad?, (power conv.)
– Cryogenic module without quad?
– Cryogenic auxiliaries?
– Vacuum system? (pumps. f. ex.)
– RTML quads? (new)
– Socket outlets
– Lighting
– Water?, HVAC?, Drain and sump?
– Other utilities?
– Transport?
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Main Linac
• Power needs of 144 m Main Linac tunnels,
according to criteria sheet
• Service tunnel
–
–
–
–
–
–
–
–
–
RF racks: 45 kVA
Other racks: 45 kVA
Socket outlets
Lighting
Water (process), water (chilled), pumps etc.?
Water ( de-mineralised)
HVAC? Drain and sump?
Transport?
Other utilities
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RTML
• From the power distribution point of view the
1330 m long RTML areas are like the LINAClike 144 m modules:
– 730 m or 5 x 144 m of them with RF
– 600 m or 4 x 144 m of them without
– The conventional services are considered
largely identical
• The detailed development of the power
distribution of the RTML areas will require a
better knowledge of the lay-out, or integration
of the equipment.
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RTML
• The long low-energy beam lines, part of the
RTML have not yet been taken into account
by the A.C. distribution.
• According to the RTML people, each quad
has to be fed from an independent P.C.
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Source e• The power demands for the e- source are
rather well defined.
– A H.V. distribution is proposed for the area.
– The costing based on the criteria sheet was
developed for Vancouver, incl. a tentative L.V.
distribution.
– The e- source installation needs a clear
definition of the interface and a lay-out to be
able to identify the unit loads and their
position
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Source e+
• A preliminary proposal has been made for
the e+ source.
– A H.V. distribution is proposed for the area.
– It covers in some detail the Undulator area.
– The power distribution of the rest of the e+
source system has been estimated as place
holder
– The costing based on the criteria sheet was
developed for Vancouver, incl. a tentative L.V.
distribution.
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2007
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Damping rings
• The power distribution in the damping ring
tunnel will be based on a 36 kV cable loop.
Or two? The loop will be designed to operate
open. The loop will allow best possible
isolation of faults.
• The loop will originate from the Central area
surface substation and will be brought to the
surface at all damping ring pits. There it will
supply, via a 36 kV/0.4 substation, the surface
area and the underground installations.
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Damping rings
• The low voltage power lines for conventional
services will originate from the alcoves. The
lines should not be longer than around 600m.
Otherwise it becomes difficult to design the
lines with a proper protection.
• It is not possible to operate with RMU-like
systems in the DR tunnel, due to the limited
diameter.
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Damping rings
Lay-out of an alcove substation.
Transformer
RMU
400/230 V Distribution switchboards
48 V system
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400/230 V
Safe supply
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Beam Delivery System
• BDS Load Breakdown
– A number of aspects are becoming clearer, but
the power distribution for the BDS is still very
much a placeholder.
– The reasonably well-defined parts are the H.V.
power links and the conventional services.
– The machine related parts are still not clear.
• Magnet loads ?
• Cooling and ventilation?
• Cryogenics ?
• The integration of this area, most likely with a
considerable amount of equipment positioned
in the service tunnel, is quite important.
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Detectors
• Detector (s)
– Power demands unknown. Exists in the costing as
place holder. Scaled on CERN experiments.
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Safe power systems
• The safe power systems will be based on
diesel generator sets (Short break) and static
UPS sets (No break).
• The dimensions of the project will probably
require high voltage generation (3.6 kV)
• Long autonomy D.C. systems should be used
for critical systems like emergency lighting
and network related safety.
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Safe Power Systems
Normal
supply
M
36/3.6 kV
X MVA
G
3.6 kV
500 m
500 m
500 m
500 m
500 m
Local safe loads
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The SCADA system
• Supervisory Control And Data Acquisition
systems should be purchased from
companies with proven expertise in the field!
• In order to obtain success with a SCADA
system you should use
– Existing, proven standard hardware
– Standard communication protocols
• Can be vendor’s protocol, if he is big enough in the trade:
Siemens, ABB, Westinghouse
– Equipment that allows for a certain number of
hardwired signals to the local control centers
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The SCADA system
• Accelerator control specialists believe this to
be a mundane activity, that they can handle
between breakfast and lunch.
• Experience has proven them wrong.
• But that does not keep them from trying.
• A SCADA system is the main source of
information about the state of the grid, the
statistics, the consumption ($!) the
maintenance etc. It should work as reliable as
the network. And that requires professionals.
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Outstanding items
• Better specifications of all area systems as
electrical consumers.
• In that sense development of lay-outs, even
simple ones. F. ex in the style of the main
linac RF unit.
• Specifications of the BDS and the experiment
as electrical consumers.
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Outstanding items
• Detailed development of a proposal for the
safe supply.
• Detailed development of a proposal for the
48 V DC supply.
• Development of the supply system for the
BDS and the Experiments
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Conclusion
• The power requirements of the project are stabilizing
• Certain area managers should sit down with the
future electrical engineer(s) and work out their power
and installation requirements in detail
• This presentation contains a selection of principles
for the construction of the ILC power distribution. It is
based on European equipment, experience,
standards and requirements.
• Good luck with the work leading to the EDR!
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