Case Study
Sludge Can Processing
Project:
Sludge Can Processing
Client: Cavendish Nuclear is the client for this project, with the control system designed and implemented by Cyclife Aquila Nuclear. The project is part of the Berkeley Intermediate Level Waste (ILW) Project, which involves processing waste stored within the Berkeley Active Waste Vaults (AWVs). Silchester Control Systems provided EC&I (Electrical, Control, and Instrumentation) services.
History: The Berkeley ILW Project requires the recovery and processing of waste stored in the Berkeley Power Station (BPS) and Berkeley Technology Centre (BTC). Among the waste streams are approximately 1400 sludge cans containing mixed aqueous sludge and solid waste. The project aims to remove, treat, and transfer the contents of these cans into Ductile Cast Iron Containers (DCICs) for transfer to an ILW conditioning facility. The empty sludge cans are then processed for disposal as Low Level Waste (LLW).
Solution
The solution involved the design and implementation of a control system for the R4 Sludge Can Processing Skid. Key components and features of the system include:
System Components:
- SCADA System: The control system comprises a SCADA machine running Factory Talk View SE,
- PLC System Allen Bradley Control Logix L30ER PLC via Ethernet IP. The PLC interfaces with an ETAP RIO island and 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. The system includes several operational sequences, such as:
- Sludge Can Retrieval and Transfer
- Sludge Can Lid Cutting and Washing
- Sludge Can Emptying and Internal Washing
- Sludge Transfer to DCIC
- 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.
- PLC Programming: The PLC code is structured into subroutines for input/output mapping, analogue processing, valve and drive control, and alarm processing. The code is modular, using Rockwell’s Studio 5000 and following IEC61131-3 standards.
- SCADA Functionality: The SCADA system provides comprehensive control and monitoring capabilities, including:
- Sequence control and navigation
- Device faceplates for status monitoring and manual control
- Alarm and interlock management
- System parameter adjustments
- Data and System Interfaces: The system interfaces with users via the SCADA PC and with other systems through hardwired I/O. It also includes provisions for data archiving, primarily for alarms.
- Environmental and Maintenance Considerations: The control system is designed for a non-redundant setup with limited fault tolerance, suitable for the project's two-year lifespan. Maintenance requirements are minimal, focusing on ensuring the system's operational integrity.
Results
The implementation of the Sludge Can Processing Skid Control System has provided a robust and comprehensive solution for managing the complex operations involved in processing intermediate level waste at the Berkeley site. The system ensures efficient and safe handling of sludge cans, with detailed diagnostics and alarm systems to maintain operational reliability. The modular design of the PLC code and the comprehensive SCADA functionality have facilitated ease of maintenance and operational control, contributing to the project's overall success.
Silchester Control Systems
Contact us to learn more about our solutions
Interested in how our expertise can benefit your projects? Get in touch with our team to discuss your specific needs and learn how we can help you achieve success through innovative automation and control solutions. Just give us a call or use the contact form, and we’ll be happy to assist you.
