Feedwater Control Digital UpgradesControl Digital …fsrug.org/Presentations 2012/Westinghouse - Digital Upgrade... · Feedwater Control Digital UpgradesControl Digital Upgrades Project

© 2012 Westinghouse Electric Company LLC. All Rights Reserved.Westinghouse Non-Proprietary Class 3

Feedwater Control Digital UpgradesFeedwater Control Digital Upgrades Project Approach & Experience

FSRUG Conference/WorkshopJanuary 23-26, 2012

Embassy Suites San Antonio TX

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Embassy Suites, San Antonio, TX

Vaughn ThomasPrincipal EngineerWestinghouse Nuclear AutomationOperating Plant Support Upgrades

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Operating Plant Support Upgrades


Characteristic Goals of FW Control Upgradespg

• Address I&C platform challenges:E i t b l– Equipment obsolescence

– Single point vulnerabilities (SPV’s)– Limitations of analog technology– Unreliable measurements

• Address I&C operational challengesU l d t / t il t– Unplanned outages/curtailments

– Operator demands– Stability, performancey

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Typical FW Control Upgrade Scopeyp pg p

• Platform (Physical)F l l (El i I/O HSI)– Fault-tolerant (Electronics, I/O, power, HSI)

– Smart/enhanced devices (sensors/positioners)– Upgraded control device interfacespg

• Application (Functional)– Signal validation– Enhanced control algorithm/logic

– Signals, compensation, controllers– Alternate modes & auto transfers

– Alternate-actions, degraded modes– Enhanced HSI (Soft -control)

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WEC FW Upgrades Timelinepg

• Generation I : Initial installed system– Analog (Foxboro H-line, 7100, 7300 Platform)– 3-Element / Independent High & Low Power (HP & LP) modes

• Generation II: Late ’80sGeneration II: Late 80s– Digital (WDPF Platform)– Enhanced 3-Element / Integrated HP & LP modes

• Generation III: Late ‘90’s– Gen II + Enhanced Features + New Platform (Ovation)

• Generation III B: > 2009• Generation III-B: > 2009– Common core design applied for BWRs

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Feed Water Upgrade Overview

I t Si l /S

pg

• Input Signals/Sensors

• Ovation Control System

• Human Factor Interfaces

• Outputs/Interfaces

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Feed Water Input Signals

● Original analog sensors often re-usedNew redundant transmitters/signals added (signal selector)

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● New redundant transmitters/signals added (signal selector)● Typically Rosemont 3051-S with HART capability are used:

– Steam Flow, FW Flow, FW Header Press (FP Turbine Runback),Steam Flow, FW Flow, FW Header Press (FP Turbine Runback), Turbine Impulse Press (Arbitrator Logic/Load Index), Steam Press

● Other Inputs (wired in)– Wide Range level (1 input , 3 loop plants / 3 inputs, 4 loop plant)– Narrow Range Level (3 inputs)

● Other SensorsO e Se so s– Nuclear Power (Arbitrator Logic/Load Index)– Feed Water Temperature (RTD’s or Thermocouples)

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– Three Speed Control Probes from turbine driven feed pump


Digital FW System Typical Configuration

• 1,2, 3 or 4 Redundant Controllers:– Dependent on design basis

• HMI > 2 Operator Workstations with soft controlsSLIM M/A St ti f l t d t l– SLIM M/A Stations for selected controls

• 1 Engineer’s/Data Base Server Workstation– Anti-virus stationAnti virus station

• Network Equipment• New Cabinets (or retrofit existing)( g)

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Typical ArchitectureypSS/EWS/DB/OWS/

Domain/OPH Server Drop 200

Security (AV) Host

IP Switch

Printer

Note 2

CISCO SY STEMS CISC OSYSTEM S

NETWORK SWITCHESPrimary Root Switch Back-up Root Switch

MAIN CONTROLROOM

COMPUTER ROOM

OperatorStation

OperatorStation

CISCOSY STEM S

PrimaryFan-outSwitch

(Note 1)

CISCOSYSTEM S

Back-upFan-outSwitch

(Note 1)

NETWORK SWITCHES

Drop 210

OCR 400 OCR 400Extended

Drop 211

Drop 10/62Loops 1 & 2

Controller ControllerDrop 11/61Loops 3 & 4

I/O Cabinet

Legend:

UTP Cable

Fiber Optic CableMedia ConverterOther T/P viaKVM Extenders

59.0 PCT

100

80

20

40

60

0

A

SP PV OUT

0

20

40

60

80

100

M L

Re jectto Lo cal

59.0 PCT

1 00

80

20

40

60

0

A

SP PV OUT

0

20

40

60

80

100

M L

Rejectto Loc al

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Digital Feed Water Main Control Room• Redundant operator stations & MCR

displays

Digital Feed Water – Main Control Room

59 0displays• SLIM M/A’s for all modulating devices

– Added redundancy for

59.0 PCT

100

SP PV OUT

100ycontroller failure

– Seamless soft control interface• Remove signal selector switches

80

6060

80

Remove signal selector switches• Remove select recorders – steam/feed

water, wide and narrow range levelR i di id l h l i di t & 20

40

20

40

• Remove individual channel indicators & replace with median

• Select indicators can remain “live”

20

0

A0

20

M L

Rejectto Local

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SLIM M/A Station


Feed Water Overview Graphic4 Loop Plant – Feed Pump Soft M/A4 Loop Plant – Feed Pump Soft M/A

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Feed Water Output Signalsp g

● Modulating Outputs to Main FW Reg ValveTypical: redundant RLI’s w/SLIM– Typical: redundant RLI s w/SLIM

– Some: redundant smart positioners (redundancy at valves)

● Modulating Outputs to Bypass FW Reg Valve– Typical: non-redundant RLI w/SLIM M/A interface– Some: redundant RLI’s w/SLIM

● Feed Pump control● Feed Pump control● Non-Integrated > Typical: non-redundant RLI w/SLIM, Some: redundant

● Integrated– Typical: non-redundant Stm Vlv Positioner Output (w/single LVDT)– Some: redundant Stm Vlv Positioner Output (w/dual LVDT, servo coil)

redundant Loop interface Output w/SLIM (to electric actuator)

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WEC Design Process for Upgradesg pg

• All control systems undergo a rigorous processHi hi l l l f i i– Hierarchical levels of extensive testing

• Heart of the process is Software In Loop (SWIL) Validation– Plant-specific engineering model to close the process loopPlant specific engineering model to close the process loop

– Models developed and refined over many projects , plant types– Strong fidelity w.r.t. to areas important to controls of interest– Thermodynamic processes

» Non-linearities over the full range of plant operation– Capability to support many-X(Real-time) for engrg analysis– Capablity to support Real-time for SWIL testing

– Ensures against field tuning and system modifications during plant startup & evolution to full power

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WEC Design Process for Upgrades (cont’d)g pg ( )

• Design Input Data Collection (Baseline Data)• Design• Design

– Functional Requirements & Diagrams– Database, Control Logic Sheets, & Graphics

• Modeling & Analysis• Modeling & Analysis– Model, plant specific (ACSL Advanced Control Simulation Language)– Setpoint Evaluation, Tuning

• Testing• Testing– Software-in-Loop (SWIL) Test [customer witness]– Factory Acceptance Test (FAT) [customer witness]

• Startup Support• Startup Support– Power Ascension Test (PAT) Guideline & On-site support

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Data and Associated Interfaces• System Information:

– Characteristics of I&C Systems being replaced

– Design basis (existing & upgraded)

• Process Information:

Organizational Interfaces:

- Project Manager- Project Engineers- Design/Integration Engineers

– Characteristics of Field Devices

– Sensors & Control Devices (Pumps,Valves, etc)

- Design/Integration Engineers- Startup Engineers

- System Engineers (Plant Systems, Subject Matter Experts)– Charactistics of

Process/Components

– SG/Rx vessel, Piping, other NSSS/BOP components

Subject Matter Experts)- Component Engineers (SG/Rx Vessel,

Valves, Pumps)- I&C Engineers

– Characteristics of Operation & Plant Performance

– Statepoints, procedures, historical data

- Operations

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High Quality Application Software Development ProcessDevelopment Process• Software Requirements Document• Software Description Document• Software Lifecycle Plan

F il M d d Aff t A l i (SW d HW)• Failure Modes and Affects Analysis (SW and HW)• Software Hazards Analysis• Processes consistent w/10CFR50 App B• Processes consistent w/10CFR50 App B

– where commercial grade application software can be applied in critical applications

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High Quality thru “Defense in Design”g y g

• Plant specific models, analysis, & testing w/application (SWIL)(SWIL)

• Application partitioning• Limited reliance on the control network• I/O default failure states• Hard control stations for critical components• Redundancy at all levels

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Lessons Learned from Project Experiencesj p

• Clear project definition Address constraints (Org/Op)– Address constraints (Org/Op)

• Project Cost/Risk Drivers– Identify & manage “First-Time” elements

• Stakeholder involvement throughout• Application of the “right”, proven technology• Disciplined design process• Thorough system testing and validation

P j t t d t l• Project management and control– Effective risk management– Focused teams, strong relationships

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Practical Implicationsp

• Early engagement of Ops– Operational needs & expectations (buy-in on features, functionality)– Training constraints

• Early recognition of schedule demands implicationsEarly recognition of schedule demands, implications• Understanding of plant/operations vs “build to spec”• Appropriate use of toolspp p

– Engineering model for dynamic testing, verification– Simulator for operator training

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• Questions?

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Documents

Feedwater Control Digital UpgradesControl Digital …fsrug.org/Presentations 2012/Westinghouse - Digital Upgrade... · Feedwater Control Digital UpgradesControl Digital Upgrades Project