Case Study
Cavendish Posting Port
Project:
Cavendish Posting Port
Client: Cavendish Nuclear Engineering Ltd
History: Cavendish Nuclear Engineering Ltd undertook the Intermediate Level Waste (ILW) Project at Berkeley Power Station (BPS) and Berkeley Technology Centre (BTC). The project aimed to recover and process mobile wastes stored within the Berkeley Active Waste Vaults (AWVs), specifically focusing on approximately 1400 sludge cans containing mixed aqueous sludge and solid waste.
Solution
The solution involved the development of the R4 Posting Port Control System, designed to provide a contained environment for the retrieval, washing, and transfer of sludge canisters between different areas while maintaining separation of ventilation regimes to prevent radioactive contamination.
System Components:
- SCADA System: A single SCADA machine running Factory Talk View Site Edition, serving as both operator station and server.
- PLC System: Allen Bradley Control Logix L30ER PLC with built-in Ethernet card, communicating with two Allen Bradley Ethernet VSD drives.
- Software Packages: Allen Bradley RS Studio 5000 and Factory Talk View Site Edition.
Operational Requirements:
- Modes of Operation: Normal mode for standard operations and Recovery mode for manual control and interlock overrides.
- Sequences: Detailed sequences for sludge can retrieval, transfer, wetting, washing, and final decontamination.
Diagnostics and Alarms:
- I/O Status: Real-time status of PLC digital inputs and outputs.
- Error Status: Monitoring of PLC and VSD fault statuses.
- Alarm Management: Active alarms and interlock overrides displayed on SCADA for immediate operator action.
System Interfaces:
- User Interface: SCADA PC located in the R4 Control Room.
- Other Systems: Hardwired I/O interfacing with external systems and equipment.
Control System Details:
- Control Panel: The Posting Port control panel is a double bay floor standing panel with a divider, housing the PLC and power circuits.
- Motor Control: Includes variable speed drives for the carriage and lid motors, and a reversing DOL starter for the discharge valve motor.
- Junction Box: A local junction box for wiring control equipment, connected to the control panel via multicore cables.
- CompactLogix PLC System: An Allen Bradley CompactLogix PLC system with standard I/O in the local rack, using Ethernet/IP protocol for network communication.
Safety Circuits:
- Emergency Stop: Integrated into the Interlock & Interface panel, disabling power to motor circuits upon activation.
- Area 200 Access: Isolating contactor removes power to motor circuits when Area 200 is accessed.
Results
The implementation of the R4 Posting Port Control System successfully achieved the following:
- Enhanced Safety: Maintained separation of ventilation regimes, reducing the risk of radioactive contamination.
- Operational Efficiency: Automated sequences and real-time diagnostics improved the efficiency of sludge canister processing.
- System Reliability: The use of robust hardware and software ensured reliable operation with minimal maintenance requirements.
Silchester Control Systems
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