Electrical Systems Partnership: Current Design Status & Critical Requirements

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This document outlines the progress and critical requirements for the Electrical Systems Partnership involving key players from the US, India, Italy, UK, France, and Poland. It covers aspects such as electrical design assistance, grounding, bonding, cable tray fill calculations, tunnel-gallery layout, and more. The completion of the electrical design review and release of important technical documents are highlighted, along with the specific power requirements and distribution setups. The use of busway for high-power distribution, generator backups, and spare capacity considerations are discussed in detail.

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Electrical Systems A Partnership of: US/DOE India/DAE Italy/INFN UK/UKRI-STFC France/CEA, CNRS/IN2P3 Poland/WUST 22-23 February 2022

Scope Charge #1a BldgI: LI: Assist in Electrical Design Electrical Connections after AUP RDS (along with Technical Integration) Bonding during installation Grounding/Bonding Cable Tray Fill CF: A/E Electrical Design Distribution Grounding Cable Tray Design Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 2

Current Design Status Charge #1a BldgI-electrical completed Final Design Review https://indico.fnal.gov/event/50102/ Worked with CF for after 100% design review to address design modifications Updated RDS as part of CD-3 refresh Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 3

Critical Requirements Charge #1c FRS and TRS are released FRS: ED0008083 TRS: ED0013928 Electrical Distribution Design Grounding/Bonding Cable Tray Fill Calculations Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 4

Critical Requirements (RDS) Charge #1c Tracks power requirements Quantities Special LOTO provisions UPS/Generator requirements Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 5

Critical Requirements (RDS) Charge #1c Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 6

Critical Requirements (AC Distribution) Charge #1c Busway used extensively for High Power RF and relay rack power distribution Flexible Minimizes floor space requirements Wireway used for generator backup Hand-off points established between CF, and LI Plug, junction box, or disconnect switch Spare capacity is built in everywhere 20% spare breakers Transformers have extra capacity that varies based on location Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 7

Critical Requirements (AC Distribution) Charge #1c Generator Wireway 208Y/120V Busway RDS Indicator 480V Disconnect Swtich Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 8

Critical Requirements (AC Distribution) Charge #1c CF Scope LI/BldgI Scope Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 9

Critical Requirements (Grounding) Charge #1c Metal to Metal Contact Required Visually Verifiable Ground CF installs main trunk lines (LINAC Gallery and Tunnel, bonded to ground bars), Building Ground (loop configuration buried outside), and ground bars (bonded to building ground) throughout gallery and tunnel CF Scope BldgI and LI Scope Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 10

Critical Requirements (Cable Tray) Charge #1c Trays are sized based on expected cable counts and 20% overhead at a minimum Tool developed in excel to track Weight Fill Dividers added for Ion Pump cables, and power supply loads where necessary Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 11

Critical Interfaces Charge #1b ISD is released ED0014385 Critical Interfaces Electrical Distribution Grounding/Bonding Cable Tray Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 12

Critical Interfaces (AC Distribution) Charge #1b LLRF Located away from noise producers Generator power Safety UPS and Generator power HPRF Large power load Separate distribution from rest of facility Phase shifted K-9 rated transformers for harmonic mitigation (extended delta 15 degree) Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 13

Critical Interfaces (AC Distribution) Charge #1b General Gallery Design Filters are built into 0U PDU units as required Line current monitors installed in every rack Validate RDS Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 14

Critical Interfaces (Grounding/Bonding) Charge #1b Cryomodules have dedicated grounding point Relay racks have pre-tapped bare metal contact point Ground bar internal to all relay racks Plated, bonded rails HPRF amplifiers have pre-tapped bare metal contact point Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 15

Critical Interfaces (Cable Tray) Charge #1b Located near all equipment Multiple tiers to separate cables Clean signal, general signal, power Crossovers located near all penetration locations Tray in tunnel coupled as closely as possible to cryomodules Additional tray provided over cryogenic equipment Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 16

Critical Interfaces (Cable Tray) Charge #1b Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 17

Critical Interfaces (Cable Tray) Charge #1b Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 18

Installation Issues (AC Distribution) Charge #1d Busway used extensively for flexible design Extra capacity allows for additional equipment Simply plug in new bus plug and new loads can be added with minimal electrician labor Wireway installed above all potential relay rack/equipment locations Extra receptacles built into baseline if expansion is needed Wireway can easily be expanded if baseline capacity is not enough Expandable UPS with extra capacity built into distribution Extra capacity built into generator and distribution Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 19

Installation Issues (Grounding/Bonding) Charge #1d Ground bars located every 100 feet or less Trunk lines located throughout gallery and tunnel Attached to all cable tray Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 20

Installation Issues (Cable Tray) Charge #1d Supported on one side only Allows for a simplified installation Extra capacity built into the baseline Unistrut used for supports which will allow for expansion if necessary Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 21

FESHM and QA Requirements Charge #2 Safety NEC and FESHM followed for all designs Cable oversized in many instances No LSZH cables without prior approval Proving difficult for some cables LOTO Switches provided for all major power loads Windowed when not powered via busway Busway disconnect switches are located 10 feet from the floor and will require hot stick actuation Keeps the user away from the equipment during use Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 22

FESHM and QA Requirements Charge #2 QC BldgI-electrical QC plan released ED0013639 Visual verification of deliveries Cable will be tested for continuity and length Tunnel-Gallery Layout and CF Process Systems FDR | Electrical Systems 22-23 Feb 2022 23