Challenges going from analog to digital controls in NPP NUCLEAR POWER EUROPE 2012

Transcription

1 ABB, Atos, 2012 Challenges going from analog to digital controls in NPP NUCLEAR POWER EUROPE _BaldorIntegration_SteeCo_1_0 June 14, 2012 Slide 1

2 Summary ABB-Atos fully integrated nuclear solution Case-study Dungeness Refurbishment of DPCS and simulator Case-study Leibstadt Change management in the control room June 14, 2012 Slide 2

3 ABB & Atos Worldgrid a nuclear I&C alliance June 14, 2012 Slide 3

4 A common and integrated nuclear solution for systems not important to safety Asset Management HSI Network Radiation Protection Turbine Control Equipement Reliability Main Control Room Controller Network Plant Process Sensor & Actuators Business Analytics Reactor Protection Nuclear Safety Data Historian P-Protocol Elec. Balance of Plant Emergency Power ADACS from Atos for data processing and control room Symphony Melody from ABB for process automation and data acquisition Simulation solution for operator training and system engineering Complete electrical balance of plant (EBoP) Plant Simulation Training, service and long term maintenance June 14, 2012 Slide 4

5 From a project specific cooperation to a strategic alliance Joint offer of complete Instrumentation and Control for plant refurbishments, new builds and simulation Combining ABB s Symphony Melody controller platform and Atos s Advanced Data processing and Control System (ADACS) A unique Nuclear solution developed for the nuclear industry based on the open platform OS Linux EDF France N4-BWR Atos Worldgrid Beloyarsk Russia BN600 ABB Dungeness B EDF Energy AGR ABB-Atos Worldgrid Strategic Partnership June 14, 2012 Slide 5

6 A common I&C history over the past 20 years The cooperation between ABB and Atos for I&C solutions in nuclear started in the early 90s, where ABB & Atos supplied and commissioned for EDF the world s first fully digital nuclear control system for the 4 plants in Chooz and Civaux in France The systems already featured fully computerized operation procedures for normal and emergency conditions 2 full-scale simulators for operator training June 14, 2012 Slide 6

7 Case-study Dungeness Refurbishment of DPCS and simulator Hunterston Torness Hartlepool Heysham Sizewell B AGR NPP PWR NPP Hinkley Point Dungeness B ABB Month DD, YYYY Slide 2 June 14, 2012 Slide 7

8 Case-study Dungeness Replacing the Old DPCS The legacy Data Processing and Control System was commissioned in 1983 using Argus 500 technology It is obsolete and British Energy (now EDF-Energy) hardly arrived to maintain it: No functional evolution left possible No spare parts available No software support available High failure rate June 14, 2012 Slide 8

9 Case-study Dungeness Project Scope Functional specification / Reverse engineering Solution Design Implementation, Data Migration, Integration Monitoring Control loops V&V Safety case support Commissioning support Warranty June 14, 2012 Slide 9

10 Case-study Dungeness Functional Scope Plant monitoring High integrity alarms calculation and display : 10-2 (~Cat B) High integrity indications calculation and display : 10-2 (~Cat B) Lower integrity alarms calculation and display : 10-1 (~Cat C) Lower integrity indications calculation and display : 10-1 (~Cat C) HMI functions (mimics, alarm lists and mgt, trends, logbook, archiving, lists, reports, ) : 10-1 (~Cat C) Operator aid functions : calculation and presentation of core parameters and core symmetry : 10-1 (~Cat C) Long term archiving : 10-0 (no classification) Digital Control Loops and Interlocks : 10-2 (~Cat B) Reactor Start Up Reactor Zone Control Boiler Feed Zone Control Gag Interlock Low Superheat Trip June 14, 2012 Slide 10

11 Case-study Dungeness Control System Architecture June 14, 2012 Slide 11

12 Case-study Dungeness Parallel Running June 14, 2012 Slide 12

13 Case-study Dungeness Lessons Learned As required by the UK Safety Authority, the project has been developed in compliance with the standards used for I&C systems of nowadays new built reactors: Compliance with IEC standard for the development of 10-2 systems Compliance with a number of new English standards A Safety Case Support Team has been supporting the Customer and the Atos team all along the project Collecting the right inputs from outdated documents, plant data and site enquiries has been a long, painful although successful process Same for establishing the specification documentation matching both the Customer and Safety Authority s expectations Team spirit, hard work and meticulous processes were keys of success June 14, 2012 Slide 13

14 Case-study Dungeness Outcomes The new Dungeness B DPCS is currently installed and running successfully the final site acceptance tests The Simulator has been commissioned and is currently used for operator training to the new DPCS The provided solution is now state of the art technology reflecting accurately all original functions with lot of capacity and flexibility for potential future extensions The Safety Case has been successfully supported to the Safety Authority satisfaction As usual for all its customers, Atos Worldgrid is committed to maintain the installed system as long as necessary, should it be over decades June 14, 2012 Slide 14

15 Case-study Leibstadt modernization Change management in the control room The I&C project of the Leibstadt Nuclear Power Plant A BWR6 reactor with 1245 MWe, first commissioned 1984 June 14, 2012 Slide 15

16 Case-study Leibstadt modernization Operation Changing in steps from push buttons, dials and tiles to screens and mouse Increasingly implemented the HSI positively impacts crew performance expanding the range of data available to the operators and reducing workload gathering plant parameters Providing shift supervisor with the plant parameter data required to work through the procedures Reducing the need for low level communication between shift supervisor and the board operators to provide the shift supervisor the plant parameters data called out in procedures. June 14, 2012 Slide 16

17 Case-study Leibstadt modernization Alarms and Trends Trends and alarm handling selectable on screen windows Alarm system, trends and graphic displays also created new sources of information that can improve the crew s understanding of, and response to, plant conditions Alarms messages are more detailed than possible with conventional tiles Alarm system requirements differ during normal operation and emergency operation Alarm messages can be filtered or grouped by subsystem, reducing the number of alarms from the tile based systems Different alarm presentation strategies can be utilized that allow operators to concentrate only on a selection they want to observe June 14, 2012 Slide 17

18 Case-study Leibstadt modernization Change in crew communication and structure Change in operation and orientation from control desks to selectable (overlapping) windows and multiple screens Board operators will gradually control the plant on mimic diagrams on the HSI With this project no computerized operating procedures are implemented, paper-based procedures are maintained today. The integration of computerized operating procedures is a further step, which may follow later in the I&C modernization Shift supervisor instructing operators to act but receiving directly information of status, trends and alarms on screen June 14, 2012 Slide 18

19 A stepped approach during refueling outages Slow transition to screens and mouse Planned and implemented in small steps over an extended period of time From the operational plant auxiliaries towards the turbine-generator island and reactor operational systems (the safety systems are a separate project) June 14, 2012 Slide 19

20 Implementation and testing Sequences of each step Regulatory requirements, I&C system concept Next modernization step Plant commissioning System tests and FAT for each modernization step in a full scale test-bed System requirements SAT System installation and commissioning Human and organizational factor requirements Operator trainings & feedback Functional and operational requirements Installation and test in plant simulator I&C system architecture and integration FAT in full scale Test-bed Detailed HW & SW design Design review System HW & SW implementation June 14, 2012 Slide 20

21 Implementation and testing Sequences of each step Regulatory requirements, I&C system concept System requirements Next modernization step Plant commissioning SAT System installation and commissioning System tests and FAT for each modernization step in a full scale test-bed Implementation in the plant simulator and functional tests Human and organizational factor requirements Operator trainings & feedback Functional and operational requirements Installation and test in plant simulator I&C system architecture and integration FAT in full scale Test-bed Detailed HW & SW design Design review System HW & SW implementation June 14, 2012 Slide 21

22 Implementation and testing Sequences of each step Regulatory requirements, I&C system concept System requirements Human and organizational factor requirements Next modernization step Plant commissioning SAT System installation and commissioning Operator trainings & feedback System tests and FAT for each modernization step in a full scale test-bed Implementation in the plant simulator and functional tests Operator trainings and feedback from crew Functional and operational requirements Installation and test in plant simulator I&C system architecture and integration FAT in full scale Test-bed Detailed HW & SW design Design review System HW & SW implementation June 14, 2012 Slide 22

23 Case-study Leibstadt modernization Slow transition to screens and mouse Mixed operation slowly redefines operator roles to be trained step by step Validation and verification on a 1to1 testbed (as a 1 st compulsory step) Implementation and V&V in the simulator together with operator trainings (2 nd step) Training in the simulator deals with training on the use of the new HSI system in handling normal operation and events. Second need is training how to most effectively use the multiple independent sources of information available in the control room, graphic displays, alarms, trends and board indicators. Training for the operators to organize their workplace to their actual needs. Different operators may choose to put up different graphic displays and trends in a collection of different windows on their screens. June 14, 2012 Slide 23

24 Case-study Leibstadt modernization Conclusions The HSI system increases the level of knowledge and understanding of individual crew members through increased availability of information. The quality of decision-making depends on the ability of everyone of the team to be aware of important control actions about to be taken and to evaluate the appropriateness of the actions based on their knowledge and perspective. The shift supervisor and board operators are able to work more cognitive. The shift supervisor concentrated on going through the procedures and guiding the operators, who can concentrate on monitoring the alarm system, graphic displays and operating the plant on the HSI. June 14, 2012 Slide 24

25 Challenges going from analog to digital controls in NPP NUCLEAR POWER EUROPE 2012 Thanks you for your attention June 14, 2012 Slide 25

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