PAC Delivers a Flexible Nuclear Power Plant Maintenance and Inspection System

Author(s):
Bryan Pudlo - R. Brooks Associates

Industry:
Energy/Power

Products:
LabVIEW, Vision, PXI/CompactPCI, Motion Control

The Challenge:
Designing a single, flexible system to control many different inspection and maintenance tools for nuclear power plans within the limited space and harsh environment of nuclear reactors.

The Solution:
Using a National Instruments programmable automation controller (PAC) hardware target, LabVIEW Real-Time, and PXI to design a single, flexible control system for five tools, with more tool designs under development.

Using NI Hardware to Design a Flexible Control Station

The control system consists of three main parts - the Operator Station 2000 (OS2000) located outside the radiation area; the PAC, or local control station (LCS), located in a low-dose area of the RCA; and a tool-end connection center (TECC) located in a high-dose area close to the inspection or maintenance location. The OS2000 connects to the LCS with a cable that offers RS232 communication, four video connections, and a TELEX audio connection. 

The LCS uses NI LabVIEW Real-Time running on an embedded controller and an 18-slot PXI chassis. The PXI chassis includes an RS232 module to control camera selection, an NI vision module for future expansion, two NI motion modules, multifunction data acquisition (DAQ) modules, and digital I/O modules for control and feedback. The RS232 module controls a video multiplexer in the LCS that switches among eight cameras, and the NI motion modules control eight different motor joints with location, direction, and current feedback. The multifunction DAQ modules take measurements from proximity, air pressure, temperature, and tilt sensors. The digital I/O modules control lights, dimmers, solenoids, clamps, and other digital components.  Finally, the system monitors the universal power supply output and notifies operators of system power loss.  

A Flexible Automation and Control System Using LabVIEW Real-Time and PXI

With the reliability of LabVIEW Real-Time, modularity of PXI, and broad range of I/O, this solution ensures operation in harsh nuclear power plant environments. We have deployed the system in four U.S. nuclear reactors so far in 2004. Because of the flexibility of the control system, Brooks engineers can design new tools and reuse the same control system, which minimizes training and setup time.  

Using LabVIEW, we found it was easy to manipulate the different inputs for the PXI modules. In addition, LabVIEW Real-Time made it very easy to deploy updates to the LCS – it merely required an Ethernet connection. And one PXI system reduced overhead, training, and shipping. With the PXI flexible solution, we deployed the system and changed tools faster than with a traditional control system. 

Future Expandability

As with most virtual-instrument-based systems, there are plans for future expansion.  The current system includes a PXI-7344 vision module, and Brooks engineers plan to upgrade the RS232 communication system to Ethernet and use the PXI vision module and NI vision products to acquire images from IEEE-1394 FireWire cameras.

For more information, contact:

Matt Jewett

R Brooks Associates, Inc.

6546 Pound Rd.

Williamson, NY

Tel: (315) 589-4000 Ext. 220

E-mail: MRJewett@rbrooks.com

 

 

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