NLC Review- Baseline Modulator

Transcription

1 NLC Review- Baseline Modulator Baseline- build today Develop Cost Model Approach _ Conventional A4odulator, Compromise of cost, reliability, efficiency and performance I modulator per 2 Klystrons

2 ,NLC Review- Baseline Modulator Design Overview Conventional Modulator 1 A4 Pulse Transformer Single oil tank- Depot maintenance Rack mount support electronics.including Charging Power Supply Charge Voltage: up to 80 kv

3 NLC Review- Baseline Modula for Baseline Modulator Requirements Parameter Desired Expected Peak Klystron Voltage 500 kv 500 kv Total Peak Current 530 A 530 A Pulse Width(usable FT) 1.5 ps 1.5ps Pulse Top Flatness 1% 2% Pulse Top Ripple 1% 2% Pulse-pulse Ripple 0.1% 0.25% Pulse-pulse Jitter Ins I Ons P.R.F. 120 Hz 120 Hz

4 NLC Review- Baseline Modula for Baseline Modulator Requirements (cont.) Parameter Desired Charging Voltage 80kV mx. Charging Supply Pwr. 65 KW Charging Supply Effic. 95+% Overall Efficiency Reliability (MTBF) 75% 15,OOOhr Expected 80kV mx. 75 KW 90% 61.5% 8,lOOhr Klysh~icmwave Deparfment Electfoflichficfowave hgheehg

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7 NLC Review- Baseline Modu. Areas of Investigation Energy Storage Capacitors Pulse Transformers Switches Layout - Size, Maintainability, cost, etc. Efficiency

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9 NLC Review- Baseline Modula for.parallel Plate Feed Test Bed w/ Parallel Plate Connection Klysfm~icfowave Depfment ElectroniclMicmwave hgheehg

10 NLC Review- Baseline Modulator Energy Storage Capacitors Studied Russian Glass Capacitors - Small size, high energy density - High dielectric constant nf, 80 kv ( 2 in series) - Assembled inductance -5OnH - Losses appeared high 5-8% - Good waveshape- 3OO+nsec risetime - Usable output efficiency w/pt- 83%

11 NLC Review- Baseline Modula for Run single glass 40-4 I kv - Failed after approx. 9 hours Believe capacitors will 75-80% rating Maximum history w/film Capacitors - Purchased film capacitors - Mutual inductance PFN helps overcome in ternal inductance of capacitor

12 NLC Review- Baseline Modula for Figure 1 PFN assembly with Sicond k15-10 capacitors Figure 1 Two types of PFN with Maxwell capacitors Klyshdkrowave Dipadmenl ElecfroniclMcmwave hgh eehg

13 NLC Review- Baseline Modula for Studying Polypropylene Film Capacitors - lonf, 80 kv - Assembled inductance -9OnH - Losses low l-2% - Good waveshape-,<400nsec risetime - Usable output efficiency w/pt- 80+% Preliminary specification written KlysWicmwave Department ElectroniclMcmwave Et@ eering

14 NLC Review- Baseline Modulator Output PFN Voltage on 4.8 Ohms Resistive Load (Sicond Cap s) _ Time, usec Output PFN Voltage on 9.6 Ohms Resistive Load (Maxwell Cap s) I Time, usec Klysfftiimwave Department ElechniclMcmwave Engineehg

15 NLC Review- Baseline Modulator w Pulse Transformer I:14 ratio design - 2 mil core material - reduced clearance margin from Risetime approached 300 nsec Stangenes North Star Research design - Double basket - Rise time slightly longer than Stangenes Preliminary specification written

16 NLC Review- Baseline Modula for Stangenns Transformer Configuration North Star Research Transformer Configuration I Klysffodhcfowave Depdment ElectroniclMcmwave Engineehg /

17 NLC Hevie w- Baseline Modulator PULSE TRANSFORMER COMPARISON Conventional Double Basket Transformer Transformer (S tangenes) (North Star) Distributed Capacitance ( air> Leakage Inductance 84 pf IlOpF 100-I 10 /JH 100-l 10 /..LH

18 NL C Review- Baseline Modula for B Switch research 0 Presently using EEV 4 gap, IOOkV, cx runs good w/double pulse trigger At these levels thyratron seems to be best present technology EEV has 3 gap thyratron to try,.cx1937 Thyra tron reliability an issue - Spec given to vendors, need to pursue KlystroFJMicmwave Lkpatment ElectroniclMicrowave hgheehg

19 NLC Review- Baseline Modula for Efficiency Tests in.test bed w/ 5045 klystron as load operated TL (Temp. Limited) to simulate PPM - combinations of: glass or film capacitor PFN s Stangenes or North Star transformer 4-gap or 2-gap thyratron Determine areas of loss - Output waveform, pulse transformer, PFN and feed, thyra tron I KlystrorJMicfowave Oepadment ElectronicdMmwave hgheerin g

20 m Modula for Efficiency Terms Power Supply Efficiency Pulse Power Transfer Efficiency Waveform Efficiency Klysbodho wave Depadmefl~ : ElectroniclMicfowave hgheehg

21 NLC Review- Baseline Modulator Klystron Beam Voltage and Current /Maxwell Capacitors w/ Stangenes Transformer Waveform Eff. - 81% Time, usec Russian Capacitors Stangenes Transformer Waveform Eff. -83% 0 1 Time?usec 3 4 Klysfmhkrowave Department ElectroniclMicrowave Engineehg

22 I Charge and Energy Balance (Stangenes Transformer) (Sicond Capacitors) (CX 1836 two gap thyratron) Total charge delivered to PFN PC Table Energy to charge PFN J Total discharge charge PC Total PFN discharge energy on primary side Total losses in the primary side: J (%I (95.81) J (%I (7.53) Including: Thyratron PFN + mismatch +etc. J (%) (3.34) (4.19) The charge delivered into the beam PC El 2 Reflected primary charge (turn ratio is 14: 1) PC c.e 5: n Total energy delivered into klystron beam J (%I x id (i&ze) a% w :e Total energy losses in transformer J (%I (4.37) CA&

23 _--.mi c ,-,._n ii Charge and Energy Balance (CX 1836 two gap thyratron) (Conventional Stangenes Transformer) (Maxwell capacitors) Table Total charge delivered to PFN nergy to charge PFN Total discharge charge Total PFN discharge energy on primary side Total losses in the primary side: The charge delivered into the beam Total energy losses in transformer

24 NLC Review- Baseline Modulator Cavacitor Pulse Discharae Energy Loss Capacitor Type Ceramic Oil Filled Film 600Volt. 3kV 0.1% 10.5% -0.2% Russian Glass 6.25% 6.5%

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26 NL C Review- Baseline Modula for Layout

27 NLC Review- Baseline Modulator m Tank Layout in process Design for manufacturability Design for performance Design to minimize cost Depot Maintenance - Thyra Won field replacement- contingency

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29 THYRATRON ASSEMBLY 7 - Anode Can 7- Anode Socket Ring 2- Thyratron Mounting Base 8 -Anode Socket Ring 3- Connectors 4- Grad. Divider (does not Isolator (does not shown) 9 -Plate Standoffs (solid) shown) 10 -Plate Standoffs (hollow) 5- Cap. Mntg. Basket I7 -Ferrite Cores (do not shown) 6- Cathode Socket Ring 72 - Thyratron Cathode Socket 73 -Thyratron Mntg I Plate Oil Mvr. Assy, Misc. Hardware, Assembly Bc Checkout

30 NLC Review- Baseline Modulator Developed Detailed Cost Model Based upon component research and vendor interactions Modulator part of High Power RF Source -$200k per unit in Qty less than IO I Klystrodkfowave Department Eldfohdk-owave Engineering

31 Estimator Data Revision WBS Definition I RF Source Klystron Lead Shielding Assy RF Drive Assy RF Protection Assy Water Manifold Assy Modulator System -Modulator Tank Assy ~. ~.. -. _._ JfV Charging Power Supply -Auxiliary Rack _Interconnecting Cables Misc. Hardware Klystron Vat ion PS Containment 4 MigMechanics~ Utilities Assembly & Checkout I.,.:,,.;,, :.,,...J :-,:.I.. ;: _::.._.\: I - :...I I;,:.: I_! ;:;.;: S I Gold._,._ : I,,. :,, ; ;;.:,, Pagelof2 9i22lsa,..:;. a:,,, :,,_,..., ~,A;;~,: : : ;.;..: I - 0, (,.I <1+:.,, :.,::::,., _, :II.. _::...,. ::;..:.,..,.. ; : ComponM -HF_Source-X-Band 2303OOxxxx 1: -, ~,:.... This Is the complete RF source with th&mqdulatoi,. high voltage power.suppiy: hrvo,klysfransj;;jrlve~;~~~~~;~ tntemonn&ts et&::.,.~.:~,;,,,,,,: :.. j,,. Thissubsystem connects to the DLDff ~~6~~~~;iiir8veguid~.va~ii; Utilities (power; water,.a/ri eto.~,;tfi6~#j&roi &stem:ommunic8tion c link,..l.:;.:.,., I. _1 and th@ low IQV~I RF &y&m. ;j.,,,,..a:,:.,s.- -, 1 _ :,_.l,. :, : I! :,, :..:r.,.!,,,:&>i(;.yi~,i :,...? -!,i : <.::::7::,,.,: lic.,s,., :...t L; :;:..,.,., 1 r ::<.I; ;,. :,.,i;.. II.., 7.. ).. _,. _, Also included is the oil containment,$6&y&m$nounting mechanlds and the.tank mbver (vehicle).and system installati6n:. ~. _.,i,~x._~. :.. -~::,. ii,.,, I I I.,,._.: The sub-systim Is assembled, ch~~~~:?:4i,~ild:tested as a subsystem in a depot prior to duiv*ciw Eind..., InStaildtion in the.gaffs I ;,...,.,:., >-..._,.. :,: _..,,;,;,x,:,.,,_ :..::;,!i,;..>. i,:.....,:..:,..::.. I :.,! :,... ~,. :- : :: : _. :.; ;. i,,.>;y.c_(.ll :s:;.,;.:....c..,,,;!,, A.,,,: :,.,.: ;., I (i i.:: : /. _ ;..:: :, :..,;,. _,_:..i / :,:,,.,. :. :: ;: F, *,,: I. I:,,.,,...,^,,~. :.,,., JCategoryI Unit 1 M&S I Labor 1 IBasis of 1 1 (E,M,L) (Measurel lantity 1 Part No. 1 Material ($/unit) 1 Equipment 1 Total 1 Type 1 Hcburs 1 Total 1 Total I Estimate I ~ ,_ I-~,------~o.oo $176, $21, $199, $ ~-~_.I@---r----..:I21 I-~ $9, $7, $16, ~._ Sub-system Test installation t----.-r Engrg &. Design._- ----~_ Notes

32 Estimator Datr Revision WBS Definition,, _,: $5,...i.:,.,,, 1.3.,:. :. (_.. I :.. :(., & Go@ :_,.. ; :.;,., 9/17/98 (_ 0 : '. Component Thyratron Assembly xxxx : ; : : : : il..,,, L : :,,, Thyratron Assembly, :;,.:,.,, :i,:,,.i /. r.,,.:l,,..:.:,..::., _. 1 ; I -- --~--..- Cathode unig~gse socket ~- -~ ~_ ring._.. -_ Grad. Divider, j. :: I,,. : L,.:.,..(._ :I.!,_. :,:j,; ~.;~.: ;,:,.. :;:._),y... ;.,. _I :..,. :.. 2 :. i,..,: 1./..)..:.,,, Category Unit M&S L a b o r - Basis of (E,M,L) Measure Quantity Part No. Material ($/unit) Equipment Total Type Hours Total Total Estimate ea 1 ~ _. --I $ L $ _-._ $19 _L_ M ea 1 SK-SG l Rl $13, $13, $ VQ- 1 :( By-pass Capacitors Capacitor mtg bracket Anode Socket ring Anode ~~.._ -- Socket Plate Standoff._... ring insulator - solid I. _ --- ~.~ I ea 21 I---- $11.24 $25.C $20.;: 11 I ~~~ $ _.. _..~. -- Engr g & Design Notes I -==-I Estimate is for a production model. Engineering design hours are for productlzing a prototypetnto piodu&idn. : ;i.,-, ;,,,..._ \.._.,:,(,.,,,.,_ I.,... I I I ~~ I I ~--.._~

33 . C Review- Baseline Modulator Risk Assessment Basic design - low risk Previously built 55OkV, 700A Need to demonstrate 500kV with selected components Polypropylene capacitors should have best reliability Thyra tron Lifetime Risk - Present SLC thyratrons > 20k hours - NLC thyratron -l/2 RMS current longer life KlystrorJMicmwave Department ElectfofliclMicrowave Engineedg

34 NLC Review- Baseline Modulator 1 Risk Assessment (cont.) Parallel klystron operation- klystron protection ( fault energy) - NLCTA- parallel klystrons in l/99 - Stray 500kV - Studying klystron arc pattern and arc energy 1

35 El NLC BASELINE MODULATOR I Test Position #03 Component Test Results Summary I I I Setup of Base Line Modulator PFN using Sicond Capacitors PFN using Maxwell Capacitors Two gap Thyratron Four gap Thyratron Stangenes X-fmr North Star X-fmr PFN losses, mismatch, and etc.,% Thyratron Losses, % Transformer Losses, % a a.4 Enerav efficiencv. % I 85.0~84.6~87.i1aa.oi i 86.oia5.6i 9o.oia2.9i 84.6ia7.5ia9.7i 90.4i i 87.11aa.oi a5 41

36 FY 99 R&D PLANS Parallel Klystron - Operation, Arc Studies, Arc Simulations Baseline Modulator - Purchase Modulator Prototype Tank - Use Mostly Existing Components - Build Prototype Tank Assembly - Use Test Position 03 Power Supply SL Gold I /26/99

37 Parallelling Klystrons Arc Isolation - Isolate stray capacitance Limit Rate of Current Rise Limit Peak Current XL4 Tests in NLCTA Study Klystron Arcs , 15OMW S-band, XL4, PPM, etc. Compare measured to Simulated SI, Gold I /26/99

38 XL4-5A Arc z 200 Q) k 6 O I Q cu -400 z > Time/4ns / -Voltage -. Current Collector Current /

39 El _.-.-- CPI DESY Klystron Arc 1-8.OE-06-6.OE-06-4.OE-06-2.OE-06 O. O E + O O 2.OE-06 4.OE-06 Time Voltage i.- -Current - j ~ IO

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41 Time Schedule Validate sensing- gas gap measurementl/ Setup NLCTA Tests- 2/l- 2/U/99 Run 2 Klystron BeamTests- 2/16-3/l/99 Build Prototype Baseline Tank- by end 99 SL Gold l/26/99

42 ISG3 MODULATORS - JAN 25-28,1999 Questions for the Collaboration FineMet (Hitachi) & Metglas (Toshiba) IGBTs SI Thyristor Other Can KEK investigate availability, pricing for (a) 500Kg-2T for prototyping, and (b) up to -1OOOT for production? Are there sources of IGBTs in Japan that can meet our technical requirements of a 5 kv device with at least 2000A pulse current and cl00 nsec switching speed? Can KEK investigate specifications, avnilability and pricing for (a) quantities of for prototyping, and (b) quantities of 40-50,000 for production? Is the SIT a possible replacement for the IGBT in our solid state design, or are its losses too high to consider this, or do we know yet without further investigation? Is an SIT stack a possible replacement for thyratrons in our Baseline design, and could we collaborate on an investigation to explore this? (AM & SG) What other avenues of collaboration would benefit the KEK and NLC programs? Does AM see areas where SLAC could assist his program at KEK?