Major Simulator Upgrade for Dungeness BJan 15, 2020 · Dungeness B Power Station Common Control Room (CCR) Simulator • Original simulator and training team based at Oldbury Training

Use of U.S. DoD visual information does not imply or constitute DoD endorsement

MAJOR SIMULATOR UPGRADE FORDUNGENESS B

15 January 2020 2020 Power Plant Simulation Conference (PowerPlantSim’20)Gregory Zakaib, Proposals Manager

• L3 MAPPS Inc. | Power Systems and Simulation

Presented at

PowerPlantSim’20

L3HARRIS | L3 MAPPS INC. © 2020 L3 MAPPS Inc. All rights reserved.

Outline

• Background• Simulator Upgrade Project

– Project Overview– Two-phase Deployment– Schedule– Challenges/Strengths/Successes

• Conclusions

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source: EDF Energy

BACKGROUND

Major Simulator Upgrade for Dungeness B

3PRESENTATION TITLE (USE INSERT > HEADER & FOOTER TO EDIT FOR ALL SLIDES)


EDF Energy’s Current Nuclear Sites

• L3Harris supported facilities– Stations

– Dungeness B– Hartlepool– Heysham 1– Hinkley Point B– Sizewell B

– Other Training Facilities– Campus– Nuclear Power Academy (Barnwood)

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Dungeness B Power Station

• Dungeness B was first commercial AGR power station to be constructed

• The £89 million contract was awarded in August 1965 to Atomic Power Constructions (APC), a consortium backed by– Crompton Parkinson– Fairey Engineering– International Combustion and Richardsons– Westgarth and Co

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Dungeness B Power Station

• Two Advanced Gas-Cooled Reactors (AGRs)– Graphite moderated / CO2 primary coolant – 4 x boiler / gas circulator units – Pre-stressed concrete pressure vessels– Single control room for both reactors

• Commercial Operation– Unit 1 (R21) 1983– Unit 2 (R22) 1985

• Current operating lifetime up to 2028

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Dungeness B Power Station Common Control Room (CCR) Simulator

• Original simulator and training team based at Oldbury Training Centre in Gloucestershire from the mid-1980s

• Simulator moved into a purpose-built building at Dungeness B site in 1999

• Unit 1 and Common plant systems simulated• Unit 2 plant systems not simulated• Hardware based on Silicon Graphics (SGI) IRIS

servers and Hytec Electronics CAMAC I/O– SGI ceased operations in 1989– Hytec ceased operations in 2016

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Legacy SGI Computers Legacy CAMAC I/O System


Dungeness B Power Station CCR Simulator

• 10 years Plant Life EXtension (PLEX) approved until 2028

• EDF Energy recognizes importance of simulator– Reliability– Maintainability– Latest Simulation Technology

• Simulator Upgrade project funded by PLEX program– Goal: Modernize simulator and ensure it can fulfil its

mission until plant end of life

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source: EDF Energy

SIMULATOR UPGRADE PROJECT


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Simulator Upgrade Contract Award Criteria

• Commercial– Compliance (conditions of

contract and tender instructions)– Supplier financial status– Pricing and payment terms– Warranty– After sales service

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• Technical– Competence (capability and

qualifications)– Previous project experience,

capability and qualifications– Risk management– Innovation (technical solution and

project flexibility)


Simulator Upgrade Contract

• EDF Energy awarded contract to L3Harris in December 2016• Contract extended in early 2017 to include replacement of legacy CAMAC I/O system

– Additional work had impact on original planned project tasks/schedule, however change in scope accommodated without impacting any key delivery dates

• Project broken down into two distinct phases

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Phase 1• New computer system• Rehost Unit 1 configuration• Unit 1 I/O system replacement• Classroom simulator

Phase 2• Unit 1 configuration updated with new

core/RCS/SG models• New Unit 2 configuration• Unit 2 panels and desk


Phase 1 – New Computer System

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Phase 1 – Rehost

• New operating systems and third-party software

• Orchid® simulation environment

• Rehost legacy simulation software to Orchid®– Source code – GFLOW models converted to Orchid® Modeling

Environment graphical models– Database– Initial conditions– Training exercises (scenarios)– Triggers (conditions)– Etc.

• New soft panels

• Converted tutor diagrams

• Stimulated/simulated external systems

• Upgraded A/V system

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Phase 1 – Orchid® Instructor Station

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• Control and monitor all aspects of simulator and trainee performance

• Fully graphical user interface with standard Windows features e.g. drag and drop, window resizing, zoom, pan, etc.

• Highly configurable (e.g. toolbars, plant parameters, feature behaviors, etc.)

• User-defined windows layout

• Client/server application

• On-line PDF user manuals

• Simulation control and maintenance functions (freeze, unfreeze, store, restore, speed-up, slow-down, DORT, etc.)

• Replay scenarios and operator actions (synchronized with the other systems such as Orchid® Multimedia Manager, etc.)

• Insertion of plant component and system malfunctions, instrument overrides and local operator actions

• Direct access to modeling schematics, active schematics and virtual (soft) panels

• On-the-fly creation of active schematics and virtual panels

• Multiple operating modes i.e. instructor, operator, engineer and student

• Built-in exam security

• Focuses on automation and data collection– Create/edit graphical scenarios– Monitor, record and trend any parameter– Monitor and track operator performance– Scenario-based Testing and Training

(SBT2) – Generate training performance records

and reports based on ANSI/ANS-3.5 requirements


Phase 1 – New Soft Panels

• Scope– Unit 1 Desk – Unit 1 Panels– Common Panels– Back Panels– Backup/Emergency

Panels– Sync Trolley

• Available from Orchid® Instructor Station

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Phase 1 – Tutor Diagrams + External Systems

• Tutor Diagrams– Legacy tutor diagrams converted to Orchid® Graphic

Editor displays using L3Harris’ pre-existing conversion tool, with fine adjustments performed as necessary– Identical look-and-feel as legacy tutor diagrams (no tutor

learning curve)– Available from Orchid® Instructor Station

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• External Systems– ATOS Digital Plant Control System (DPCS)

– Stimulated (complete) DPCS in full scope simulator– Simulated alarm list with Orchid® Control System in

classroom– POLARIS Plant Monitoring System (PMS)

– Partially simulated PMS HMI with Orchid® Control System in full scope simulator and in classroom


Phase 1 – Upgraded A/V System

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• Hardware– 6 analog cameras and microphones retained– 2 new digital encoders (4 channels each) – New A/V server

• Software– Orchid® Multimedia Manager

– A/V recording and playback– Time-synchronized with the simulator for

synchronized audio-video playbacks– Connectivity with debriefing room– Preview of all cameras in a mosaic display

for monitoring at all times– Stores files using industry-standard “AVI”

format


Phase 1 – Unit 1 I/O System Replacement

• Hardware– Legacy CAMAC I/O system replaced with new

Beckhoff EtherCAT compact I/O system– 1-to-1 I/O points

• Software– Orchid® Input Output

– Provides online diagnostics– Hardware and communication failure

indications sent to Instructor Station (i.e. Simulator Confidence)

– Conversion from engineering units to electrical units

– Panel sleep

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Phase 1 – Unit 1 I/O System Replacement

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Before After

Legacy CAMAC I/O controllers replaced with interface to mate existing

I/O wiring and connectors to new BeckhoffI/O installed on DIN rails


Phase 1 – Classroom Simulator

• 5 Student Workstations (capability to run independent simulations)

• 1 Standard Orchid® Touch Interface Bay– Utilized for testing at L3Harris– Delivered to Dungeness B during

Phase 2

• Mobile Instructor Station with Orchid® Instructor Station

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Phase 2 – Dual-Unit Simulation Strategy

• Capability to operate Unit 2 stand-alone or in conjunction with Unit 1 to simulate complete power station• Similar strategy implemented by L3Harris at Heysham 1• Benefits of dual-unit simulator

– Provides very representative and realistic control room environment especially important for plant with common control room

– Enables training of full shift crews following plant processes and procedures– Enhances shift crew teamwork– Enhances control room communication skills while directing actions to be performed on a specific unit (communication

more complex than before)– Allows opportunity for control room personnel to prioritize tasks to perform on training scenarios affecting both units

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Phase 2 – New Models

• Unit 1 Legacy Updated – New Reactor Core Model

– Comet Plus™ Reactor Core Model / Orchid® Core Builder – New Boiler and Reheater Model

– ANTHEM™ / Orchid® Modeling Environment– New Gas Circuit Model

– ANTHEM™ / Orchid® Modeling Environment– Boundary Interfaces

– Feedwater, startup vessel, main steam– RCS gas bypass circuit

• New simulator load for Unit 2 created– Unit 1 used as starting point and updated to match R2

conditions

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Phase 2 – Unit 2 Panels and Desk

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• Full Hard Panels solution– Replace existing Unit 2 Panel mockup with new structure and new operable instruments– Retain Unit 2 Desk structure / add new operable instruments

• Best physical fidelity/realism (i.e. look-and-feel)• Enable most effective training

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Existing Unit 2 Panel mockup New Unit 2 Panel Instruments



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PHASE I (Rehost and I/O Replacement) Rehost Design Rehost Development and Integration Rehost FAT I/O Design I/O Prototype Build and Test At Dungeness I/O Production Build and Factory Test Install at Dungeness

Phase 1 SAT Support EDF Training (Remotely from L3M)

Phase 2 (Model Updates + Unit 2 Panel / Desk)Unit 1 Model Development and IntegrationUnit 1 Model FATUnit 1 Model SATUnit 2 Model Development and IntegrationUnit 2 Model FATUnit 2 Panel/Desk DesignUnit 2 Panel/Desk DevelopmentUnit 2 Panel/Desk Integrated FATSite Work: Panel Disassembly / New Panel Install

Unit 2 Panel/Desk and Model Update

2017 2018 2019Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q1

2020Q4 Q1 Q2 Q3 Q4

• Contract award: December 2016• In Service: November 2019

Project Timeline

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Ph 1 Unit 1 Training

Ph2 Takeover

P2 Unit 1 Training

BAR Sched Template (QTR)

2017201820192020

StartFinishQ1Q2Q3Q4Q1Q2Q3Q4Q1Q2Q3Q4Q1

PHASE I (Rehost and I/O Replacement)PHASE I (Rehost and I/O Replacement)

DesignMon 1/16/17Fri 3/10/17 Rehost Design

Development and IntegrationMon 2/6/17Fri 8/4/17 Rehost Development and Integration

FAT Mon 6/5/17Fri 8/25/17 Rehost FAT

DesignMon 4/24/17Tue 8/8/17 I/O Design

Prototype Build and Test At DungenessWed 8/2/17Tue 10/10/17 I/O Prototype Build and Test At Dungeness

Production Build and Factory TestWed 10/11/17Wed 1/31/18 I/O Production Build and Factory Test

Install at DungenessMon 2/5/18Fri 2/23/18 Install at Dungeness

Phase 1 SATMon 2/26/18Fri 3/23/18Phase 1 SAT

Support EDF Training (Remotely from L3M)Mon 3/26/18Fri 6/22/18 Support EDF Training (Remotely from L3M)

EDF Energy Take-Over - Phase 1Thu 8/30/18Thu 8/30/18

Phase 2 (Model Updates + Unit 2 Desk/Panels) Phase 2 (Model Updates + Unit 2 Panel / Desk)

Development and Integration1/1/18Fri 8/31/18Unit 1 Model Development and Integration

FAT10/22/1811/9/18Unit 1 Model FAT

Unit 1 Model SAT

1/1/19Unit 2 Model Development and Integration

Unit 2 Model FAT

DesignMon 3/26/18Fri 7/13/18Unit 2 Panel/Desk Design

DevelopmentFri 7/13/18Wed 4/24/19Unit 2 Panel/Desk Development

FATWed 4/24/19Tue 5/14/19Unit 2 Panel/Desk Integrated FAT

Old Panel Disassembly / New Panel InstallationMon 6/17/19Fri 6/28/19Site Work: Panel Disassembly / New Panel Install

SAT Unit 2 Panel and Model UpdateMon 7/1/19Fri 7/12/19 Unit 2 Panel/Desk and Model Update

Phase 2 - Take Over CertificateFri 10/18/19Fri 10/18/19

``

Sheet1

Task NameDurationStartFinish

PHASE I (Rehost and I/O Replacement)

Rehost

Design40 daysMon 1/16/17Fri 3/10/17

Development and Integration130 daysMon 2/6/17Fri 8/4/17

FAT 60 daysMon 6/5/17Fri 8/25/17

I/O Replacement

Design77 daysMon 4/24/17Tue 8/8/17

Prototype Build and Test At Dungeness50 daysWed 8/2/17Tue 10/10/17

Production Build and Factory Test81 daysWed 10/11/17Wed 1/31/18

Site Work

Install at Dungeness15 daysMon 2/5/18Fri 2/23/18

Phase 1 SAT4 wksMon 2/26/18Fri 3/23/18

Support EDF Training (Remotely from L3M)13 wksMon 3/26/18Fri 6/22/18

EDF Energy Take-Over - Phase 10 wksThu 8/30/18Thu 8/30/18

Phase 2 (Model Updates + Unit 2 Desk/Panels)

Model Update

Design76 daysFri 5/18/18Fri 8/31/18

Development and Integration126 daysFri 8/31/18Fri 2/22/19

FAT76 daysFri 1/18/19Fri 5/3/19

Unit 2 Desk/ Panels

Design80 daysMon 3/26/18Fri 7/13/18

Development204 daysFri 7/13/18Wed 4/24/19

FAT15 daysWed 4/24/19Tue 5/14/19

Site Work

Old Panel Disassembly / New Panel Installation10 daysMon 6/17/19Fri 6/28/19

SAT Unit 2 Panel and Model Update10 DaysMon 7/1/19Fri 7/12/19

Phase 2 - Take Over Certificate0 daysFri 10/18/19Fri 10/18/19


Challenges

• Schedule – New I/O system upgrade scope added, without impacting the final delivery date of

Phase 1

• Behavior of retained legacy models and higher fidelity Orchid® replacement models– Increased the need for discussions and workshops with plant experts

• Maintenance of multiple configurations – Synchronizing field updates from Phase 1 (rehost) training into Phase 2 during

model development– Synchronizing changes between Unit 1 and Unit 2 configurations during the

deployment lifecycle

• EDF Energy support stretched between testing in Montreal and supporting training at Site– Overcome by deferring non-critical items to later phases– Provision of training load at EDF for remote support– Use of automated testing features of Orchid® Instructor Station to reduce face-to-

face testing time*

• Obsolescence of panel instruments– 3D printed many devices to replicate look-and-feel of originals

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*Automated Testing

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Recorded Data

Alarm Logs

Simulator Actions

Operator Actions

Scenarios

SBT2 • Collated & organized• Saved in 1 folder• Can be zipped

and/or protected• Saved in common

formats (.doc, .xls, .pdf).


Project Strengths/Successes Expressed by EDF Energy

• Performance– EDF Energy pleased with project progress – L3Harris’ processes, policies and procedures in all areas of operation (Project

Management, Contract Management, Quality Assurance, Engineering) are professional

• Cooperation & Communication– Cooperation and communication between L3Harris and EDF Energy on highest

standard and allowed project to progress to meet customer requirements

• Flexibility– L3Harris’ flexibility in scope change management and commercial

arrangements allowed EDF Energy to focus on project with responsive L3Harris team

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source: EDF Energy

CONCLUSIONS


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Conclusions

• Project completed successfully to EDF Energy’s satisfaction• Dungeness B Simulator now on modern and easy-to-use/maintain

platform: Orchid®– New high-fidelity models provide most realistic responses and easier to

maintain using L3Harris’ state-of-the-art graphical modeling tools– Orchid® Core Builder– Orchid® Modeling Environment

• Obsolete computers and I/O system no longer threat to training program • Enhanced training capabilities with classroom simulator• Upgraded simulator sustainable until the end of power station life• New Unit 2 simulation, desk and panels integrated with Unit 1 simulator

provides most representative and realistic control room environment– Allows training on dual-unit scenarios – not possible before

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Major Simulator Upgrade for�Dungeness BOutlineBackgroundEDF Energy’s Current Nuclear SitesDungeness B Power StationDungeness B Power StationDungeness B Power Station Common Control Room (CCR) SimulatorDungeness B Power Station CCR SimulatorSimulator Upgrade ProjectSimulator Upgrade Contract Award CriteriaSimulator Upgrade ContractPhase 1 – New Computer SystemPhase 1 – RehostPhase 1 – Orchid® Instructor StationPhase 1 – New Soft PanelsPhase 1 – Tutor Diagrams + External SystemsPhase 1 – Upgraded A/V SystemPhase 1 – Unit 1 I/O System ReplacementPhase 1 – Unit 1 I/O System ReplacementPhase 1 – Classroom SimulatorPhase 2 – Dual-Unit Simulation StrategyPhase 2 – New ModelsPhase 2 – Unit 2 Panels and DeskPhase 2 – Unit 2 Panels and DeskPhase 2 – Unit 2 Panels and DeskProject TimelineChallenges*Automated TestingProject Strengths/Successes Expressed by EDF EnergyConclusionsConclusionsSlide Number 32

Documents

Major Simulator Upgrade for Dungeness BJan 15, 2020 · Dungeness B Power Station Common Control Room (CCR) Simulator • Original simulator and training team based at Oldbury Training