Thermal Test Complex
Thermal Test Complex Automation and Control
Customer: Sandia National Laboratories
Figure 1. Thermal Test Complex |
The Thermal Test Complex (TTC), shown in Figure 1, is a multi-laboratory facility for testing full-scale weapons systems in real fire environments. TTC offers three thermal modes (gas fire, liquid fire, and radiant heat) with systems to accurately control test conditions and analyze fires. The complex features a 7-story, 60-foot diameter fire test cell, called the FLAME cell (Figure 2), with water-cooled walls and airflow equipment; an 84-foot long low speed wind tunnel, called the Cross Flow Fire Test Facility, or XTF; and a 5.2 Megawatt radiant heat test cell.
Figure 2. TTC Flame Cell
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Ktech developed the integrated software control system for the 23,000 square foot TTC facility.
The control system manages the severe high temperature environments created in the three test chambers, performs data acquisition functions, and provides administrative and security controls.
The size of the facility demanded a distributed control system. The scope of the processes and equipment controlled included air flow, heat sources, cooling systems, fuels and utilities, and totaled 783 control and monitoring points.
Figure 3. A Cooling Water Tower
Object-Oriented Code on a PAC
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We built programmable automation controllers (PACs) with embedded control software for facility subsystems using FieldPoint and LabVIEW RT. By embedding the hardware control logic on the PACs, we reduced the processor load on our control computers and provided autonomous control of our hardware for continuous operations, such as freeze protection. We implemented data logging, alarm handling and security features using the Datalogging and Supervisory Control Module (DSC). Using TestStand, we developed a test sequence engine with in-test hot backup functionality.
Ktech performed design, development, documentation, installation, test and qualification services. Our modular, robust solution reduces Sandia’s manpower needs, limits personnel exposure to electrical and fire hazards and increases testing efficiency.
