# Presentation: 030197

## TESLA TDR MODULATORS

- FERMILAB

- Dan Wolff/Howie Pfeffer

**Notes:**
Frequently, presenters must deliver material of a technical nature to an audience unfamiliar with the topic or vocabulary.  The material may be complex or heavy with detail.  To present technical material effectively, use the following guidelines from Dale Carnegie Training®.

Consider the amount of time available and prepare to organize your material.  Narrow your topic.  Divide your presentation into clear segments. Follow a logical progression. Maintain your focus throughout. Close the presentation with a summary, repetition of the key steps, or a logical conclusion.

Keep your audience in mind at all times.  For example, be sure data is clear and information is relevant.  Keep the level of detail and vocabulary appropriate for the audience.  Use visuals to support key points or steps.  Keep alert to the needs of your listeners, and you will have a more receptive audience.

## TESLA MODULATOR SPECS

- Dan Wolff/Howie Pfeffer

## POTENTIAL MODULATOR TECHNOLOGIES

**SNS **– High Frequency Switcher
- +   Small Size
- +   Passive circuit on secondary to control spark energy deserves further investigation
- Switcher probably has to be installed in the tunnel
- -    HV/HF Transformer is tricky.  Is it reliable?

-    **Miss-Matched PFN** – Russian Idea, not built
-    No Bouncer Needed
-    Interesting, could be more reliable
-    Need to build one

-    **FNAL Modified** – One built by Industry?
-    IGCT’s, Constant Power CPS, New Caps?
-    I think this is what is in the TDR – getting more details

-   **FNAL** – with updated technology

- Dan Wolff/Howie Pfeffer

## TDR vs. FERMI MODULATOR

- KLYSTRON MOUNTED HORIZONTALLY – IN TUNNEL
- Oil Leaks, Oil Containment (ES&H issue)?

-    LONG CABLES: PULSER-TO-TRANSFORMER

-    CAPACITOR BANK
- 	TDR uses newer “Hazy” polypropelene capacitors

-    SWITCH TECHNOLOGY
- 	TDR uses IGCTs (newer devices based on theGTO)
- 	Eliminated the Backup Switch

- Dan Wolff/Howie Pfeffer

## TDR vs. FERMI MODULATOR - Continued

- CHARGING POWER SUPPLY
- -   More Complicated
- -   Driven by rather severe requirements
- 20 kV Source, 200 MVA Short Circuit Impedance, +/- 0.5% Reg

-     ABB Hv Pulse Transformer

- Dan Wolff/Howie Pfeffer

## MODULATOR CABLES – Xsection

- Dan Wolff/Howie Pfeffer

## MODULATOR CABLES - waveform

- Dan Wolff/Howie Pfeffer

## MODULATOR CABLES – Comments

- Cable Looks Like Power Distribution Type – well known costs
- Cable Rating – checked for all enclosures and penetrations?

-     Matching Cable Impedance to Klystron Load
- 	Is it really necessary?
- 	Modulator pulse rise time is fairly slow.
- 	A terminating RC at the pulse transformer should be sufficient

- Dan Wolff/Howie Pfeffer

## MODULATOR BACKUP SWITCH- Comments

- Backup Switch is used in coordination with cap bank crowbar to minimize the energy deposited during a klystron spark in the event of a failure of the main switch.

- The TDR modulator left out the backup switch under the assumption that the large resistance of the ABB pulse transformer secondary would absorb most of the energy during a spark.

- Recent computer simulations have indicated that due to the bouncer circuit, much more energy is available then assumed for the TDR design.

- Further consideration is needed to determine if the risk to the klystron is acceptable, or if changes to the modulator circuit will be needed.  The cost of the backup switch is less then 5% of the modulator cost.

- Dan Wolff/Howie Pfeffer

## MODULATOR CPS – AC Mains

- Allowed distortions to the mains
- The German standard VDE 0838 or the equivalent European standard EN 61000 defines the amount of distortions that are allowed to be produced by a consumer of electrical energy.  These distortions are defined as relative voltage changes d with
- 		d    = allowed relative voltage changes
- 		U   = mains voltage
- 		DU = variation of mains voltage
- 		DS = variation of power due to the modulators
- 		Ssc = short circuit power of the mains

-   For TESLA operating at 5 Hz this value d is < 0.5%.

- Dan Wolff/Howie Pfeffer

## MODULATOR CPS - Topology

- Solution Adopted in TDR:
- 	-    Stack up a number of industry-supplied PWM power supplies
- 	-    Provide for Constant Power Charging by using a DESY developed self-learning regulation system.
- 		The capacitor charging waveform, stored in the regulator memory, is modified (learned) based on the requirement for constant power draw on the AC supply.
- 	-   Other power supply solutions possible with the same regulation scheme.

- Dan Wolff/Howie Pfeffer

## MODULATOR CPS - Comments

- AC Mains Restriction Severe
- FNAL
- 	Footprint Area:   2% of 15 Hz
- 	Tests Done Recently With MI:    5% with 2 sec. ramp
- 	MI Pulsed Power:   10% with 1.5 sec. ramp
- 	13.8 kV System 500 MVA SC (200 MVA)
- 	13.8 kV Distribution Local – not shared with general public
- 	Sharing Level is at the 345 kV level (SC Huge)

-    Charging Power Supply Complicated
- Floating PWM power supplies
- Number of components
- Complicated Regulation
- Reliability? (CPS is the most complicated part of mod.,)

- Dan Wolff/Howie Pfeffer

## TDR COST ESTIMATE 

- MODULATOR, PULSE TRANSFORMER, and CHARGING PS
- $299.5K ea.                  (572 units = $172M)
- Price Based on Mass Production Study by PPT of the existing commercially built modulator.  No mention is made of PPT’s track record on similar studies.
- One manufacturer is assumed

-    HV CABLES
-    $72.2M for 1000km
-    Cost based on an estimate from Cable Manufacturer
-    Cost includes cable terminations and tunnel installation

-    Price Estimates Provided by Stefan Choroba

- Dan Wolff/Howie Pfeffer

## TESLA COST ESTIMATE – Misc

-     EDIA, and host lab labor?
-    Service Building Floor Plan?
-    Installation costs
- 	-    Rigging
- 	-    Cable pulls and terminations
- 		HV cables costed under HV Cables
- 		AC Power costed under infrastructure
-    Testing Plans:
- 	-    Facilities: Final Assembler (industry)
- 	-    Lab Labor: Has an estimate (didn’t quote it)
-    Installation Plans
- 	-   Staging: shipped directly to service buildings
- 	-   Storage: none needed
- 	-   Schedule:  Not provided

- Dan Wolff/Howie Pfeffer

## FERMI MODULATOR – Parts Cost

- Pulse Transformer:    $108k
- Pwr Transformer:       $ 50k
- Main Cap Bank:         $ 31k
- Cabinet:                      $ 15k
- Other:                        $126k
-                Subtotal:     $330k
- IGBT Switch             Subtotal:  $ 50k
- Modulator Controls   Subtotal:  $ 40k

-   Pulser Parts Cost

-    TOTAL:   $420K

- Dan Wolff/Howie Pfeffer

**Notes:**
In your opening, establish the relevancy of the topic to the audience.  Give a brief preview of the presentation and establish value for the listeners.  Take into account your audience’s interest and expertise in the topic when choosing your vocabulary, examples, and illustrations.  Focus on the importance of the topic to your audience, and  you will have more attentive listeners.

## FERMI MODULATOR – Total Cost

- LABOR ESTIMATE:
- (Total parts cost) – (Pulse Transformer)
- $422k   -   $108k   =  $314k

-    TOTAL COST ESTIMATE

-     PULSER PARTS ESTIMATE:         $420k

-    TOTAL:   $735k

-    RF MODULES (Spark Detection):      $12k    (AWAG)

-    LESS Filament and Solenoid PSs:    - $10k

- Dan Wolff/Howie Pfeffer

## FERMI MODULATOR – 572 Units

- “RULE OF THUMB” for mass production:
- 5%/unit decrease for each 2x increase in number of units
- 2**x = 580,    x = 9.18
- (.95)**(9.18) = .62
- Cost per unit = $458k

-    COST ESTIMATE FOR 572 UNITS

-     SINGLE MODULATOR COST:    $735K

-    TOTAL:   $262M

-    NOT INCLUDING INSTALLATION

- Dan Wolff/Howie Pfeffer

**Notes:**
If you have several points, steps, or key ideas use multiple slides.  Determine if your audience is to understand a new idea, learn a process, or receive greater depth to a familiar concept.  Back up each point with adequate explanation. As appropriate, supplement your presentation with technical support data in hard copy or on disc, e-mail, or the Internet.  Develop each point adequately to communicate with your audience.

## FERMI-BUILT MODULATOR

- IGBT Switch:
- Using Original Devices:   25% reduction in switch cost
- Eliminating the Backup Switch:  20% reduction
- Using New Higher Voltage Devices:
- 50% reduction in cost and physical size

-    Updated Technology

-    Main Capacitor Bank:
- Using New “HAZY” Self-Healing Polypropylene Capacitors
- 50% Reduction in Cap Cost and Physical Size

-    Modulator Controls:
- Using Lab G type – SM Components, fewer cable interconnects
- 25% reduction in parts, 50% reduction in labor

- Dan Wolff/Howie Pfeffer

## FERMI-BUILT MODULATOR

- Using New Higher Voltage Devices and eliminating the backup switch:
- $60k savings in labor and parts

-    Updated Modulator Cost

-    Main Capacitor Bank:
- Using New “HAZY” Self-Healing Polypropylene Capacitors
-   $30k savings in labor and parts
-   $5k savings in Cabinet,  Reduced Service Building Size!

- Controls Upgrade
- $30k Savings in parts and labor

- Dan Wolff/Howie Pfeffer

**Notes:**
Determine the best close for your audience and your presentation.  Close with a summary; offer options; recommend a strategy; suggest a plan; set a goal.  Keep your focus throughout your presentation, and you will more likely achieve your purpose.

## FERMI-BUILT MODULATOR-  Updated Modulator costs, continued

- 5 Hz Operation
- $50k Savings in parts and labor

-    TOTAL:
- 	 $735 - $175 = $560k      (24%)
- 	Inflation Since 1996 (5 yrs at 3%/yr) = 16%
- 	1.16 x $560 = $650k

-    TOTAL – 572 Modulators
- 	“Rule of Thumb” for Mass Production
- 	.62 x $650k = $400k

- Dan Wolff/Howie Pfeffer

## FINAL COMMENTS

- Technically, there is very little risk associated with the TDR modulators.  The technology is well-known and various modulators have been operating at TTF for years.

- There are a few technical design issues yet but they, for the most part, have to do with cost optimization.  For example, the choice of charging power supply technology and the use (or not) of a backup switch.

- In brief, the TDR assumes a single company be responsible for  modulator construction and testing.  The completed modulators would be shipped directly to the service buildings where the host lab would be responsible for final installation and commissioning.

- Dan Wolff/Howie Pfeffer

## FINAL COMMENTS - continued

- The TDR modulator cost seems low ($300k) as compared to the Fermilab modulator scaled to the TDR ($400k).

- Factors that may account for this difference:
- 	-  The Fermilab built modulator cost estimate uses lab labor
- 	-  The “rule of thumb”  for mass production may not apply

- THERFORE, the accuracy of the cost estimate within 30% depends on the validity of the mass production study performed by PPT (German firm).  Understanding this company’s experience (success) with similar studies would be key to placing some confidence level in the cost estimate.

- Dan Wolff/Howie Pfeffer