462624 - Synopsis - Power Control & Regulating System for AGS Motor Generator Set (Cycloconverter)

Specification / Technical Document

This document specifies the technical requirements for a power controller/regulator, referred to as a cycloconverter. This system is intended to regulate the input power to a 9 MW wound rotor induction motor that drives a 95 MVA salient pole Generator for the Alternating Gradient Synchrotron (AGS) Accelerator at Brookhaven National Laboratory (BNL).

• Power Regulation: The cycloconverter must control the AC input power to the motor by dynamically controlling the motor rotor currents, managing both real and reactive power. Reactive power should be near zero, and real power should be constant throughout a cycle.

• Operation: The system must operate in a mode where total input power equals power lost in each cycle, maintaining a constant rotational speed at the beginning of each cycle within a super cycle.

• Components: Requires antiparallel six-pulse thyristor bridges (or equivalent), with specified voltage and current ratings for semiconductors. Includes requirements for overtemperature protection, overspeed protection, overpower interlocks, and ground fault protection.

• Sensors & Instrumentation: Requires various transducers and sensors for measuring real and reactive power, rotor and stator currents, rotor voltages, speed, slip, and frequency. Panel meters and displays are required for monitoring.

• Control System: A complete control and protection system using a Siemens PLC (or approved equal) is required, with local and remote control capabilities. Failsafe design principles are mandated.

• Testing: Includes factory acceptance testing, such as control checkout, continuous operation under load for 24 hours, bandwidth and response time measurements, and high potential tests.

• The document outlines technical specifications and requirements for a contractor to supply and potentially install this system.

• Contractors must propose designs that meet all specified requirements, including details on semiconductor types, cooling methods, and control system architecture.

• Proposals should include a list of proposed manufacturers for components.

• Specific details like the number of monitoring points and interface requirements will be finalized at the Design Review.

• Not specified in this document.

• This document is a "DRAFT" specification.

• It references numerous applicable documents, standards, and drawings.

• BNL intends to keep the existing cycloconverter as a spare unit and may switch the incoming 13.8 kV line between systems.

• A new dedicated transformer for the new cycloconverter is preferred, and existing switchgear may be reused.

Statement of Work (SOW) / Performance Work Statement (PWS)

This Statement of Work (SOW) outlines the requirements for the procurement of a power controller/regulator for the AGS Motor Generator Set (Cycloconverter) at Brookhaven National Laboratory (BNL). The system will control the input power to a 9 MW wound rotor induction motor driving a 95 MVA salient pole Generator.

• Design, manufacture, inspect, test, deliver, partially install, and commission the Cycloconverter Power Regulator (Cyclo).

• The Cyclo must interface with the existing motor and control AC input power by dynamically controlling motor rotor currents to manage real and reactive power.

• Provide overvoltage protection devices at the cycloconverter output.

• Supply all necessary circuitry to synthesize and synchronize the three rotor currents.

• Provide detailed recommendations for installation and engineering assistance during installation.

• Supply installation instructions, equipment drawings, point-to-point wiring schedules, rigging instructions, and cabinet layout information.

• Reactive power should be as close to zero as possible.

• Real power must remain constant throughout a chosen physics cycle.

• Input average power requirements can range from 1 MW to 9 MW.

• Acceptance Test Procedures (ATP) must be approved by BSA and ensure all test requirements are met.

• The document does not explicitly state the period of performance, but it details milestones such as Preliminary Design Review (8 weeks after award) and Final Design Review (12 weeks after award).

• Installation and commissioning will occur at BNL.

• Contractor must have documented experience with building cycloconverters of similar class and size.

• All control software must be subject to review and approval by BSA.

• Adherence to Environment, Safety, and Health (ESH) requirements, including pressure safety, fire, material handling, and electrical safety.

• Compliance with applicable standards such as ASME B30.26 (Rigging Hardware) and NFPA 70 (2020).

• Documentation must be in English and provided in electronic and physical copies.

• Contractor must maintain a documented quality assurance system.

• Value Engineering proposals are encouraged for improvements in performance, reliability, quality, safety, or cost reduction.