Project overview
We developed a replacement crane control and drive system for an application on a nuclear power facility in the UK. The crane system was over 20 years old, and although the mechanical side of the crane was regularly serviced and maintained to a high standard, the main issues were due to the obsolescence of the drives and the control systems.
The challenge
Working in a nuclear facility on a critical system presents issues, including the level of standards and procedures that are required. We have vast experience in situations where control and automation are critical and complex.
The client wished to update the crane system to benefit from enhanced functionality while ensuring the same or an increased level of safety and control.
Scope of works
The control package replacement was based on Siemens SIMATIC Safety Integrated S7-1500F advanced controllers and connected to a newly installed PROFIsafe SINAMICS S120 VFD servo drive system. This was linked through an integrated PROFINET interface.
Within the control room, a new HMI was developed to provide the operator with a clear view of the crane system, including a mimic of the location and functionality of the crane, verifiable by the new CCTV systems.
The complete package of control hardware, software and drives was engineered, procured, integrated and subjected to factory acceptance testing (FAT) at our premises prior to being installed. Our dedicated site installation team of multidisciplinary engineers and technicians completed the installation and strenuously tested as a complete system as part of a site integrated test, before it was handed over to the client.
Conclusion
Working closely with the client, we understood the implications of the high-profile project with no margin for error. We successfully ensured continued operation and a safe upgrade of this crane, providing a full turnkey package that will be supportable for the next 20 years.