DNB Power and Control System Information and Interim Safety Procedures. Version draft 5/06/08

Transcription

1 DNB Power and Control System Information and Interim Safety Procedures Version draft 5/06/08

2 DNB Power and Control System Information There are four sources of power for the DNB in the power supply and control systems, 480V 3-phase for the DNB HVPS (50kV) Supply, 480V 3-phase for the DNB Arc Supply, 380V 3-phase for the DNB Controls and smaller supplies and 120V for the PLC, pump controls and gauge controllers). See Figure A for the one-line diagram with arc flash references, Figure B for Map of equipment and control points, Figure C for Arc Flash Calculations sheet and Figure D for an approximate cell equipment layout. The 480V 3-phase DNB HVPS (50kV) Supply and DNB Arc Supply service is experimental power from the 13,800V high yard supply breaker (CELCO 13.8kV 1000MVA S/C X/R=2.734). This breaker is controlled locally by manual control in the cubicle or remotely by NSTAR. See Figure 1. It feeds a 13.8kV to 4160V step-down transformer (12/16/20 MVA OA/FA/FA, located in the C-Mod High Yard) with secondaries protected by a 5kV, 600A breaker that is controlled by a bat-handle switch in the C-Mod control room mounted in the breaker control rack (top right hand position). See Figures 2, 3a and 3b. The 5 kv breaker can only be closed manually using the local or remote switch, but can be opened remotely by the switch or by the DNB operator interface Main Power screen. See Figure 4. The 4160V supply feeds a GE Limit Amp located in the NW C-Mod Power Room. The Limit Amp system includes contactors and 200 A fuses and feeds a 4160V to 480V stepdown transformer also located in the NW C-Mod Power Room. See Figure 5. The Limit Amp contactors can be opened or closely locally, remotely in the cell or remotely by the DNB operator interface Power screen. See Figures 4,5 and 6. This service feeds two separate 480V fused disconnects, a 100A service to the DNB Arc Supply rack #N5 and a 450A service to the DNB Equipment racks #N1-N3 See Figures 6 and 7. These disconnects can only be operated manually at the disconnect switch The 380V control and small power supply service is fed from the C-Mod setup lab DPH-1 Circuit 8 via the circuit breaker #C-Mod Cell Distribution Panel A Circuit 10 located on the North wall of the cell toward the west corner. See Figure 8. This breaker protects the line to the 480V to 380V step-down transformer located on the C-Mod Cell South wall, west side. See Figure 9. A 30A fused disconnect switch protects the control and small power supply service rack #5 See Figure 10. The input to rack #N5 also has an input circuit breakers for the controls and small power supply service. See Figure 11. From the input to rack #N5, the 380V service is routed to DNB racks #1-3 downstairs in the cell and to the DNB Control Rack N4 with CAMAC and controls located on the DNB level. Figure 12 shows the DNB Control Rack located adjacent to the DNB. This rack houses CAMAC Controls, Digitizers and Instrumentation circuitry. The rear door of this rack must remain locked at all times except for maintenance.

3 Figure 13 shows the power inductor used in the high voltage power supply system. It is located in a protective cover adjacent to Blue DNB control rack on the lower level of the C-Mod cell. The control rack houses the system PLC, gauges and gauge controllers as well as the turbo pump controller. The 120V power source is Panel F Circuit V is exposed at the PLC and elsewhere in the rack and doors must be kept closed and locked except during maintenance or troubleshooting. Figure 14 shows DNB Equipment racks #N6 and N7. These racks contain equipment and circuits referenced to the high voltage power supply. Doors are to remain closed and locked at all times except during maintenance or troubleshooting, when all safety procedures must be followed. Figure 15 shows the DNB HV Cable Snubber Tank and Arc Discharge Plasma Box. All covers are to be secured in place while the beam is operating. During maintenance or troubleshooting, all safety procedures must be followed. Figure 16 shows the high voltage power supply tank mounted above the DNB. The tank is filled with insulating gas (SF 6 ). Safety procedures must be followed when accessing this tank for maintenance or troubleshooting. Figure 17 shows the DNB PLC Rack and its 120V Service Panel.

4 Interim Safety Procedure Interim safety procedures are to be followed to provide personnel and equipment safety until the design and implementation of a mechanically and electrically interlocked system is completed. The interim safety procedures are based on the lockout/tagout procedures and minimum personnel and administrative requirements for work on electrical equipment guidelines to be found in the following links: All personnel to be working on the DNB systems must read, understand and follow the referenced procedures and guidelines and the following to be qualified to work on the DNB system. Normal Operation - For normal operation a qualified technician or engineer must be available on site at all times to respond to emergency situations requiring de-energizing of any DNB equipment. The qualified technician or engineer will know the power source for each piece of equipment in the DNB, know the location of all breakers and switches and be trained in turning them off and on safely. The qualified technician or engineer will be responsible for determining that all system equipment covers, equipment rack cabinet doors and high voltage supply rack doors are secure, closed and locked before closing the 5KV breaker, closing the Limit Amp or fused disconnect switches used to supply these racks. The normal DNB startup procedure must be followed and checked each time before the DNB is to be run The keys for the racks are to be kept in the key lockbox at the DNB operator workstation in the C-Mod control room at all times except during maintenance or troubleshooting and as required for normal operation turn-on and off. The keybox is to be kept locked at all times with the keys inside unless the equipment is being accessed following safety procedures. For normal operation, the qualified technician or engineer must open two racks, #N1 and #N5 to turn on the various power supplies and controls. Arc Flash Hazards for each situation must be understood and followed when working on and turning on or off any equipment. See the Arc Flash Hazard Calculations Sheet and one-line diagram with arc references in Figures A and C. Maintenance or Troubleshooting Operation For maintenance or troubleshooting operation at least one qualified technician or engineer (depending on the minimum personnel guidelines for working on electrical equipment) must be available on site at all times to respond to situations requiring energizing or de-energizing of any DNB equipment. See the lockout/tagout procedures for required number of breaks that need to be made in related source power before any rack is to be opened for maintenance or troubleshooting for personnel safety. The technician or engineer must understand the circuits in each cabinet to determine the source power for that cabinet.

5 Interim Safety Procedure, cont d Before equipment rack entry the circuits must be tested to insure that circuits are dead and grounded if required for safety. If cabinets need to be left open to allow troubleshooting, test equipment should be set up with circuits deenergized before turning on power. Appropriate warning tape or barricades should be set up to prevent others from entering the test area. Arc Flash Hazards must be determined and appropriate protective clothing and distances maintained when working on equipment. A qualified technician or engineer must be present at the location of any open cabinets during tests of equipment not requiring the experimental cell to be closed. During any tests requiring high voltage with open cabinets or exposed high voltage, the cell should be cleared and closed before high voltage tests are conducted. Work on live circuits is to be avoided where possible.

6 Figure A. DNB System One-Line Diagram

7 Figure B. DNB Power System Map

8 Figure C. DNB Power System Arc Flash Calculations

9 C-Mod Cell Power Panel A Ckt 10 feeds 480/380VAC Transformer Top View in Cell Upper Level DNB Level Lower Level 480/ 380VAC Transformer HV Racks HV Snubber Enclosure 380VAC Fused Disconnect Rack #N6 Rack #N7 Rack #N5 Rack #N1 DNB DNB HVPS Tank Tokamak HV Access Panel Rack #N2 DNB CAMAC Rack N4 Rack #N3 DNB PLC 480VAC HV Supply Fused Disconnect fed from 4160/480VAC Transformer in Power Room NW kV LimitAmp Controls. (LimitAmp in NW feeds 4160/480VAC Trans. DNB Arc Supply and HVPS) 480VAC Arc Supply Fused Disconnect (4160/480VAC Transformer in Power Room NW21-194) Ind. Figure D. DNB System Cell Equipment Layout (approximate)

10 Figure kV Breaker in C-Mod High Yard Cubicle Feeds 13.8kV/4160V Transformer Figure kV/4160V Transformer in C-Mod High Yard

11 5kV Breaker Control Switch Figure 3a. DNB 5kV 800A Breaker in C-Mod High Yard Cubicle. Figure 3b. DNB 5kV Breaker Control, C-Mod Control Room

12 5kV Breaker Open Only Control Limit Amp Control Figure 4. DNB Operator Interface Main Power Screen In C-Mod Control Room

13 Limit Amp Local Controls 4160/480V Transformer Figure 5. Limit Amp and 1000kVA 4160/480V Transformer on East Wall in NW C-Mod Power Room

14 Limit Amp Control Arc Supply Control Figure 6. Limit Amp Control and Arc Supply Fused Disconnect on Cell Bottom Level, South wall, East of DNB PLC Rack, and DNB Racks # N3-N1 and N5

15 Figure 7. DNB HVPS 480V 450A Fused Disconnect on Cell Bottom Level, South wall, East of DNB PLC Rack and DNB Racks #N3-N1, N5

16 Figure 8. DNB 480V/380V Service on Bottom Level, North Wall, West side. The Panel is fed from the C-Mod Setup Lab DPH-1 Circuit 8. Circuit 10 feeds the 480/380V Transformer

17 Figure 9. DNB 480V/380V Transformer for Control Power/ Aux Power Supplies. Located on Top Level, South wall, West side.

18 Figure 10. DNB 480V/380V Fused Disconnect for Control Power/ Aux Power Supplies. Located on Top Level, South wall, West side adjacent to DNB Rack #N5.

19 DNB Rack #N3 DNB Rack #N1 DNB Rack #5 DNB Rack #N2 contains power supply equipment for the HVPS and provide a pushbutton contactor control and Emergency Stop Button. Phase power on indicators are provided. DNB Rack #N5 houses the Arc Power Supply Breaker, Aux. Power Supply Breaker, 3 Grid Power Supply Breaker and BMPS breaker. All front and rear doors must be closed and locked for normal operation. Figure 11. DNB Racks # N3-N1 and N5 Located on Bottom Level, South wall

20 Input Service Caution - 380/220 VAC control power! Figure 12. DNB CAMAC Rack #N4. Rack houses CAMAC Controls, Digitizers and Instrumentation. 380VAC service is from 380/220VAC Fused Disconnect via Rack #N5 terminal blocks.

21 DNB PLC Rack with PLC, Gauges, gauge controllers and pump controllers. 120VAC Circuits inside. (See Fig. 17, also.) DNB Power Inductor. Covers must be in place for normal operation. Figure 13. DNB Power Inductor connects to circuits in Rack #N2 Located on Bottom Level, South wall of C-Mod Cell. Blue Rack adjacent to inductor houses DNB PLC and Controls

22 DNB Rack #N6 DNB Rack #N7 Doors are to remain closed and locked at all times except during maintenance or troubleshooting, when all safety procedures must be followed. Figure 14. DNB Racks #N6 and N7 located on Top Level, West of DNB in C-Mod Cell. These racks house power supply equipment referenced to the DNB 50kV Power Supply.

23 DNB High Voltage Cabling Referenced to High Voltage Power Supply DNB Arc-Discharge Plasma Box DNB High Voltage Cable From High Voltage Supply (Blue Tank above DNB) to Rack # N6 and N7. DNB HV Snubber Tank All Equipment covers must be in place for normal operation. During maintenance or troubleshooting all safety procedures must be followed. Figure 15. DNB HV Snubber Tank and Arc-Discharge Plasma Box house power supply equipment and cabling referenced to the DNB 50kV Power Supply.

24 Figure 16. DNB HV 50kV Power Supply (Blue Tank). Tank is filled with SF 6 Insulating Gas.

25 Input Service to DNB PLC Controls 120VAC, F Port Power Panel Ckt. 17. DNB PLC Controls Rack adjacent to DNB Rack #N3 on lower level South wall. Figure 17. DNB PLC Controls Rack (Blue) and its 120V Service Panel