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55_040324_CLN_01.doc

***TO: S WARKALA***

***FROM: C NEUMEYER***

***SUBJECT: IE POWER DESIGN REVIEW RESULTS AND RELEASE FOR FABRICTION***

S Ramakrishan and the writer visited IE Power, Inc., on 23 March for the
purposes of a plant tour and design review.

The review was successful.

Therefore, in accordance with the specification, please authorize IE
Power (in writing) that they may proceed with fabrication. In addition,
please notify them of the following items.

1)  Minutes of design review meeting and action items (including PPPL
    responses) are attached. IE Power shall follow up with their action
    items, *including a revision to their design document*.

2)  IE Power shall, in accordance with the specification, furnish
    biweekly progress reports.

Cc: M Ono S Ramakrishnan A Von Halle M Williams

[IE Design Review Meeting Notes]{.underline}

1)  PPPL to indicate incoming and outgoing cable lug hole spacing. *See
    post meeting item*

2)  Gland plate centerlines to be relocated directly over bus bar
    centers.

3)  Incoming control wiring to be segregated behind insulating panels.

4)  Revised cabined weight 4350 lbs.

5)  PPPL to indicated limits on fork lift spacing and thickness x width
    of forks.

6)  Third beam to be added under cabinet to better distribute load. *See
    post meeting item*

7)  Cooling water connections to be located for bottom/side entry,
    recessed within cabinet and accessible via removable plate.

8)  Kirk Key logic should release key only when input disconnect switch
    open and cap discharge switch closed via removal of motive power
    source to discharge switch. PPPL to provide Kirk Key logic diagram
    and indicate PPPL vs. IE scope of work. *See post meeting item*

9)  Only front panel meter required shall be for the cap bank voltage.

10) PPPL to utilize only single pole grounding in SDS to eliminate short
    circuit condition on cap bank. This will facilitate fusing.

11) Input DCCT to be 1kA

12) Additional resistance of 1-2mOhm is foreseen for series inductor and
    internal cables.

13) IE Power shall reconfigure discharge switch/resistor to three
    parallels to increase redundancy. Temperature sensor on resistor to
    be provided.

14) Hipot shall be to ground, not across IGBTs.

15) All insulating breaks associated with control/firing circuits shall
    be included in the hipot test.

16) Hydrostat test shall be 1.5 x operating pressure = 1.5\*120 = 180
    psi minimum.

17) 80 microhenries and adjustable resistance will be available for
    dummy load.

18) Water circuit to be changed from 3 parallels to 6 parallels to suit
    lower differential water pressure.

19) Referring to PPPL comments on drawings: C1..twisted pair has been
    marked up. C2..will provide cross-references on drawings. C3..pins 1
    & 14 of J1 are outputs. These will be relocated to the top two
    terminals of the block. C4..Vref input will be via isolated inputs
    AD215 Analog Devices. C5..will be changed from Vd to Vdc.
    C6..signals will be added to D-14781.

20) IE will add a pull-down resistor for Vref.

21) PPPL shall clarify details of Permissive and Enable signal
    implementation. Probably the Permissive will be a contact closure
    and the Enable will be an open collector. *See post meeting item*

22) Load-open detection is not required.

23) Remote enable and reset signals shall be applied simultaneously to
    all three subunits; individual sub-unit signals are not required.
    *See post meeting item*

24) Tin plated joints are acceptable to PPPL.

25) IE to send control circuit drawings to PPPL when they are ready.

26) Damper RC circuits to be retained but values TBD until testing.

27) IE to revise design report and forward to PPPL.

28) Need separate ground cable connection points for disconnect switch
    compartment and main compartment.

# Post Meeting Items

1\) In prior correspondence, PPPL noted...

"Because of the low resistance of the PPPL load, the IR drop will very
low (3333 A \* 20mOhm = 66V max, which is only 6.6% duty cycle.  Most
operations will be performed at very low duty cycle. Will the sawtooth
control scheme be sufficiently accurate at low duty cycles?"

The IE response was...

" In our experience, the sawtooth control scheme is adequate for narrow
pulse width required with PPPL load (BNL load is very similar to BNL/SNS
load). On the other hand, in BNL/SNS unit we have encountered the
problems due to asymmetry in turn-on/turn-off times of IGBT switches. To
solve this problem, we have devised unique circuit techniques and this
information will be provided in the design report.\"

This point was briefly discussed at the design review. However, a more
detailed elaboration, including supporting analysis, needs to be
included in the design report as previously promised.

2\) PPPL response to meeting item 1)

The incoming (bottom entry) power cables from the PPPL equipment to the
disconnect switch compartment are 2-1/c 500MCM, 5kV shielded power
cables (one conductor to (+) bus and one conductor to (-) bus). The
outer diameter of the cable is 1.25". The cable lug is Burndy YA34-2N.
See Burndy website...

<http://ecatalog.fciconnect.com/fci/datasheet.asp?PN=YA342N&FAM=509>

  ----------------------------------- -----------------------------------
  Wire Size                           500 kcmil

  Stud Hole Size                      1/2"

  Stud Hole Spacing                   1-3/4"

  Barrel Length                       Long Barrel

  Tongue Angle                        Straight

  Tongue Width                        1.52"
  ----------------------------------- -----------------------------------

The outgoing (top entry) power cables from the SPA to the PPPL equipment
are 3-4/c 500MCM, 600V power cables, one 4/c cable from each sub-unit
(two parallel conductors to each sub-unit (+) bus and two parallel
conductors to each sub-unit (-) bus). The outer diameter of the cable is
2.5". Cable lug is same as above for incoming cables.

3\) PPPL response to meeting item 5)

Note that PPPL has to perform several lifting and moving operations at
the site in addition to the operations that may be necessary during
shipment. Most of these operations will not utilize a fork lift.
Considering this, please arrange to ship the equipment on an appropriate
pallet, and change the spacing between the tubes to 60" center to center
instead of 32" (ref. IE drawing C14782). With this spacing, and the
third beam at the center (see meeting item 6)) the floor loading will be
within appropriate limits.

4\) PPPL response to meeting item 8)

IE Power shall supply a Kirk Lock/Key which shall be released when the
cap bank discharge switch is closed and its motive power has been
removed. SPA rear access doors (3) and disconnect switch compartment
door (1) shall utilize Kirk Locks/Keys (total of four (4)) to be
supplied by PPPL but mounted by IE Power. These locks and keys will be
used in conjunction with other locks and keys in PPPL equipment to
ensure that the SPA is positively de-energized prior to entering PPPL
equipment and that PPPL equipment is positively de-energized prior to
entering the SPA. The SPA disconnect switch itself need not be
interlocked by a Kirk Key, only the door to the disconnect switch
enclosure. We assume that that the control (front) compartments of the
SPA can be opened any time without exposing hazards above 120VAC.

5\) Preference on Input Disconnect Switch

PPPL would prefer that the input disconnect switch be a double pole
double throw 600A switch, instead of the ABB switch proposed by IE
Power. In one position the switch connects the DC source to the SPA. In
the other position it disconnects the SPA from the source and connects
each terminal of the SPA to ground. This is necessary to provide a
safety ground when accessing the SPA. A recommended switch is Filnor
Catalog# A-7726.

6\) PPPL response to meeting item 21)

For the enable signal, since fast response is important, an optocoupler
(H11N1 (<http://www.fairchildsemi.com/pfPrint/H1/H11N1-M.html>) or
equivalent) shall be provided.

For the permissive signal, PPPL will provide a 125VDC (+/- 10%) signal.
Signal present (V ≥ half nominal voltage) shall correspond to the
"permissive" condition, signal absent (V\< half nominal voltage) shall
correspond to the "not-permissive" condition.

7\) Clarification on meeting item 23)

PPPL now desires (as shown on the IE drawings at the review) to retain
one enable signal per sub-unit (total 3) instead of one per the entire
SPA.

However, as agreed at the meeting, only one reset signal is required for
the SPA (although three could be provided if more convenient). This
signal will be a normally open, momentary closed, optocoupler with the
following characteristics....

> \- Capable of switching 28 vdc at 16 milliamps
>
> \- Nominal on-time is 300 milliseconds
>
> \- Von less than 0.5 volts at 16 ma
>
> \- Off-State leakage current 30 microamps (max) at 28 v

8\) Clarification on "Fault Not" Signal

Per specification paragraph 3.2.4.3.2, PPPL requires a "Fault Not"
signal. This signal is not shown on IE C14784, unless it is the
equivalent of the "PSON" signal shown. IE Power needs to clarify this
point. In any case, the characteristics of the PPPL input device for
this signal are as follows (two modes are available to choose from)...

> [24 vdc mode]{.underline}:
>
> Input ON voltage: 20 to 30 vdc
>
> Input ON current: 10 milliamps
>
> Input OFF voltage: Below 4 vdc
>
> [5 vdc mode]{.underline}:
>
> Input ON voltage: 2 to 5 vdc
>
> Input ON current: 10 milliamps
>
> Input OFF voltage: Below 0.5 vdc