NIPAC Nuclear Power Plant Maintenance and Monitoring Control System Solutions

Application areas:

Energy

challenge:

Design a self-contained, flexible system that works within the confined space and harsh nuclear reactor environment to control a variety of different monitoring and maintenance tools in nuclear power plants.

Solution:

Using NI's programmable automation system (PAC) hardware platform, LabVIEW RT, and PXT, a flexible control system was developed for five tools and will continue to be developed for more tools.

Products used:

LabVIEW, LabVIEW RT (real-time), motion control, PXI/CompactPCI, programmable automation controller (PAC), machine vision

Diablo Canyon is one of the nuclear power plants that R. Brook uses LCS for monitoring.

Design a Flexible Control Station Using NI Hardware

This 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 the low radiation area within the radiation area; and the tool terminal connection center (TECC) near the monitoring and maintenance location. The OS2000 is connected to the LCS through a line that provides RS232 communication, four video connections, and TELEX audio connections.

The LCS uses NI LabVIEW RT running on an embedded controller and an 18-slot PXI chassis that includes an RS 232 module to control camera selection, an NI video module for further expansion, two NI motion control modules, multifunction data acquisition modules, and digital I/O modules for control and feedback. The RS 232 module controls a video multiplexer in the LCS that switches between eight cameras, while the NI motion module controls eight different motors that combine guard, direction, and current feedback. Multifunction DAQ modules measure data from proximity, pressure, temperature, and inclination sensors. Digital I/O controls lighting, dimmers, solenoids, and other components. Finally, the system monitors all power supplies and provides operators with system power-down reports.

Using LabVIEW RT Module and PXI Hardware to Build Flexible Automation Control Systems

With reliable LabVEIW RT, modular PXI, and a wide range of I/O channels, this solution can ensure operation in the harsh nuclear power plant environment. As of 2004, we have deployed this system in four nuclear reactors across the United States. Its flexibility allows Brooks engineers to smoothly design new tools and reuse the same control system, thus saving training and configuration time.

During use, we found that LabVIEW can easily process different input data from PXI modules. In addition, LabVIEW RT can also be used to upgrade LCS very easily, with only an Ethernet connection. A single PXI system can also reduce management costs, training costs, and transportation costs. With the flexible PXI solution, we can deploy systems and replace tools faster than in traditional control systems.

Future expansion

As with most virtual instrumentation-based systems, there are many ways to expand in the future. The current system includes a PXI-7344 vision module, and Brooks engineers are planning to upgrade the RS232 communication system to Ethernet and use the PXI vision module and other NI vision products to acquire images from IEEE-1394 interface cameras.