Steps towards a large-scale I&C modernization at the Paks NPP to support the planned plant service time extension

Transcription

1 Paks NPP Steps towards a large-scale I&C modernization at the Paks NPP to support the planned plant service time extension T. Túri, B. B Katics, J. Végh, E. Holló,, I. Varga vej@sunserv.kfki.hu IAEA - Second International Symposium on Nuclear Power Plant Life Management (PLiM( PLiM) Shanghai, China, October, 2007

2 Presentation overview Introduction to Paks NPP Completed modernization projects: RPS, plant computers, radiation monitoring I&C modifications for power uprating: core monitoring, pressure control Preparations to replace traditional I&C Scope, schedule of I&C reconstruction Paks NPP I&C modernization 2

3 Paks NPP in brief Four VVER-440/213 units ( ) 1987) Present total capacity = 1890 MWe Production in 2006 = 13.5 TWh ( 37.6%) Safety enhancements ( ) Power uprating to 108% ( ) 2009) Plant service time extension (30 50 y) Paks NPP I&C modernization 3

4 Paks NPP in the Hungarian Transmission Network MAVIR Zrt. Paks NPP I&C modernization 4

5 Unit 4 = 108% Unit 3 = 100% Unit 2 = 100% Unit 1 = 108% Paks NPP I&C modernization 5

6 Safety system refurbishment Motivation and functional improvements: Compliance with requirements (single-failure, fault tolerance, fail-safe features, seismic qualification) Higher level of automation, less operator actions Full-scope diversity, testability and self-diagnostics Full reconstruction between Result: triple-redundant, redundant, fully digital RPS Tools: Teleperm XS, Space, ProfiSim Extensive use of simulator for V&V tests Paks NPP I&C modernization 6

7 CONTROLLED PROCESS DIV a SENSOR SET RED 1 DIV b SENSOR SET RED 2 SENSOR SET RED 3 DIV a DIV b DIV a DIV b 10YZ 10YZ1 10YZ4 10YZ7 C1 PI C2 C1 PI C2 C1 PI C2 C1 PI C2 C1 PI C2 C1 PI C2 Architecture of the new safety system IPL DIV a C3 PO OR PO IPL DIV b C3 IPL DIV a C3 PO OR PO IPL DIV b C3 IPL DIV a C3 PO PO OR IPL DIV b C3 RPL RED 1 C1 C2 C3 ECCL DLS RPL RED 2 C1 C2 C3 ECCL DLS RPL RED 3 C1 C2 C3 ECCL DLS PO PO PO Y X W ACTUATOR CONTROL ACTUATOR CONTROL ACTUATOR CONTROL... ACTUATORS... ACTUATORS... ACTUATORS RED: DIV a, b: RPL: IPL: Redundancy Diverse "a", "b" Reactor Protection Logic Integrated Protection Logic Point - to - point individual wired link Multiplexed optical link Physical separation Process connection EP ACTUATOR CONTROL Point - to - point individual wired link or Paks NPP I&C modernization 7 multiplexed communication link 2V3... EP ACTUATORS

8 Animated RPS logic diagram as displayed in the window of the ProfiSim tool Paks NPP I&C modernization 8

9 Process computer system (PCS) I. Most important Paks PCS functions: Data acquisition from the technology (+ RPS GW) Signal processing & display, data storage Serving other plant systems with processed data No active control functions, only monitoring Full reconstruction between Parallel work with RPS modernization Unit 1-4, 1 simulator + Plant Info Centre New items: CSF monitoring + EOP display Paks NPP I&C modernization 9

10 Process computer system (PCS) II. Architecture of the unified PCS: Redundant 100 Mbps network (Fast Ethernet) Redundant Scada servers, disributed processing Supervisor syst. (self-diagnostics + reconfiguration) Unified HMI for the CR operators and O&M personnel HTML-based (WEB) services for external PCS users Unified hardware and software tools: Professional, PC-compatible servers (rack mounted) Win-NT 4.0, ifix Scada shell, MS SQL Server 2000 Multi-level access control and data protection Paks NPP I&C modernization 10

11 Architecture of the new process computer at Unit 1 Paks NPP I&C modernization 11

12 Main display format of the new PCS Paks NPP I&C modernization 12

13 RPS state overview picture Paks NPP I&C modernization 13

14 Integrity CSF picture Paks NPP I&C modernization 14

15 Radiation monitoring systems 1 st step: environmental monitoring system Full system reconstruction between monitoring stations (γ, aerosol, noble gas, iodine) renewed + 11 new γ monitoring stations installed 3 water monitoring posts + 2 ventilation stacks Industrial field network + central Scada processing 2 nd step: internal radiation monitoring Full system reconstruction between New dosimetry control room with large display panel Scada components with limited soft-control Paks NPP I&C modernization 15

16 Radiation detectors Large Panel Display Dosimetry control room Operator workstations MGP / BITT Containment doors Remote I/O Remote I/O Air sampling valves Data concentrator Control PLC Control PLC To remote workstations Dual I&C Field LAN WEB server Plant industrial LAN Scada server Scada server Unit 2 process computer room Scada server Unit 3 process computer room Scada server Scada server Scada server Scada server Scada server Protected control post (bunker) Operator workstations Printers Printers Printers Printers Architecture of the new internal radiation monitoring system Paks NPP I&C modernization 16

17 Power uprating project Most important plant modifications: New fuel (3.82% enrichment, profiled, 12.3 mm lattice pitch) Decreased hydroaccumator pressure (59 35 bar) New, more stable primary pressure control New HP turbine inlet nozzle, modified turbine control Replacement of high-pressure preheaters Several minor enhancements on the secondary side Modernized generator cooling New, reconstructed core monitoring system Paks NPP I&C modernization 17

18 VERONA core surveillance system Main objectives and improvements Increase system capacity to support power uprating Replacement of the obsolete hardware and network Full SW modernization and porting to Windows New, more accurate reactor physics calculations Integration of the standard Paks core design code Modernization of the human-machine interface Modern SW tools: SQL, OPC, Scada-based HMI Full reconstruction between Status: U1,3,4 + simulator = O.K. U2 = 2008 Paks NPP I&C modernization 18

19 Architecture of the new VERONA system Paks NPP I&C modernization 19

20 Main display format of the new system Paks NPP I&C modernization 20

21 History of reaching first 104% then 108% power at Unit 4 (2006) Paks NPP I&C modernization 21

22 Primary pressure controller Problems with old controller: Insufficient long-term stability Rough discrete characteristics for heaters and spray Power uprating required a more precise control Solution = installation of a new controller: Built from functionally + spatially distributed PLCs Industrial Ethernet for communication + field buses Continuous analogue control ( bar) Highly stable primary pressure control ensured Paks NPP I&C modernization 22

23 Scheme of the new pressure controller Paks NPP I&C modernization 23

24 25 q be [ t/h ] Injection valves 20 YP11 S403 YP11S YP11 S YP11 S Electrical heaters III. II. I p [ bar ] IV. 720 V Characteristic of the new controller P [ kw ] Paks NPP I&C modernization 24

25 View of the main controller Paks NPP I&C modernization 25

26 Old New Comparison of the behaviour of the old an new pressure controllers Paks NPP I&C modernization 26

27 Present I&C situation Safety I&C systems: Fully reconstructed, present state is satisfactory Traditional (non-safety) I&C systems: Approaching their expected service time Modernization is needed for service time extension Plant information & supervision systems: Most of them was (or will be) reconstructed Their present state is (or will be) satisfactory Paks NPP I&C modernization 27

28 Preparations and studies Development of the I&C functional model Definition of appropriate I&C functional groups Elaboration of a formal methodology to describe I&C Development of a plant I&C database (U1 completed) I&C pilot project = tasting the pudding Complete re-engineering of a system (make-up wtr) Testing the I&C engineer is the programmer idea Using, testing various tools (ProfiSim, Space etc.) Selection of the final design and implementation approach and applicable tools Paks NPP I&C modernization 28

29 Scope and schedule of the I&C works Paks-specific specific guide (based on IEC TR 62096) Major steps identified for the Paks case: Establishment of the I&C project framework Preparative activity (e.g. requirements specification) Design phase Manufacturing phase Installation phase Proposed time t schedule Preparations and project launch: between Site installations at the units: between Paks NPP I&C modernization 29

30 Plant network MCR ECR SMS OP OP PCS M GW M SMS OP OP PCS E GW E LAN ECR LAN MCR MSI MCR GW A GW B MSI ECR IT Primary circuit IR Secondary circuit IS Turbine RPS Y M/S_PLC RPS X M/S_PLC RPS W M/S_PLC M/S_PLC IG Generator IJ Electrical M/S_PLC I LAN Y I LAN X I LAN W I LAN A I LAN U AC S_PLC AC AC S_PLC AC AC S_PLC AC S_PLC AC S_PLC AC M IY Safety M M M M M M IX Safety IW Safety IA Reactor M IU External Safety Class 4 SINEC H1 Gigabit Ethernet (optical) GW: RPS gateway computer SMS: Safety Monitoring System MSI: Monitoring & Service Interface Safety Class 3 SINEC L2 Industrial Ethernet (optical) MCR: Main Control Room OP: Operator workstation Safety Class 2 Wired connection Industrial Ethernet (twisted pair) ECR: Emergency CR PCS: Plant Computer System Scheme of the new process control system Paks NPP I&C modernization 30