Process Control Migration of 50 LPH Helium Liquefier

Two helium liquefier/ refrigerators are operational at VECC while one is dedicated for the Superconducting Cyclotron. The first helium liquefier of 50 LPH capacity from Air Liquide has already completed fifteen years of operation without any major trouble. This liquefier is being controlled by Eurotherm PC3000 make PLC. This PLC has become obsolete since last seven years or so. Though we can still manage to run the PLC system with existing spares, risk of discontinuation of the operation is always there due to unavailability of spare. In order to eliminate the risk, an equivalent PLC control system based on Siemens S7-300 was thought of. For smooth migration, total programming was done keeping the same field input and output interface, nomenclature and graphset. New program is a mix of S7-300 Graph, STL and LAD languages. One to one program verification of the entire process graph was done manually. The total program was run in simulation mode. Matlab mathematical model was also used for plant control simulations. EPICS based SCADA was used for process monitoring. As of now the entire hardware and software is ready for direct replacement with minimum required set up time.