Kilroot Power Station – emergency electronics re-engineering
Obsolescence recovery of critical PSU used at Kilroot Power Station
Challenge: A problem that’s all too common is support of an electronics design that has got old and can no longer be produced because its electronic components have become obsolete. Such a situation is often the case with very successful designs that perhaps stand the test of time a little too well. This was the problem at Kilroot power station in Northern Ireland where a critical electronic power supply developed in the 20th century, of which there was dwindling stock through natural wastage, was threatening power provision for Northern Ireland. The function of this power supply was so important that its failure compromised the ability of the power station to make electricity available to its customers.
The Kilroot power supply was two supplies in one: a main and auxiliary to provide back up if the main failed. The negotiation between these two supplies was managed by discrete logic gates in a very 1980s style. This further complicated the circuit because it was entirely bespoke.
Kilroot were in a position where the number of working supplies was only just greater than the requirement.
Something needed doing urgently – like in months not years.
Solution: There were some key activities that needed pulling together as quickly as possible:
- Quick assessment of dated logic circuits to define their functions for replication.
- Test and definition of the power supply performance
- Rapid identification of power supplies via a reputable distributor because there would have been no point in re-inventing an entirely bespoke power supply. It was just necessary to find a standard one and implement control electronics.
- Rapid design
Skills:
- Rapid digital design synthesis
- Excellent supplier relationship management (power supplies)
- Prompt design
- Dynamic transition from design to manufacture.
- Management of design through manufacture.
Journey: Only one batch of the new supplies was ever to be produced. The power station was coal fired and on a path to be decommissioned. The whole process took less than 3 months to fully working substitute power supplies. It leaves the EM team believing this is one of our USPs.
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