a road to successful integrated dcs upgrades

7/31/2019 A Road to Successful Integrated DCS Upgrades

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A Road To SuccessfulIntegrated DCS Upgrades.

Tim IsaacsSan Onofre Nuclear Generating Station

(SONGS)

Southern California Edison


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Preview (why we are here).

Description of the SONGS DCSUpgrade.

SONGS DCS Team.

Maintenance DCS Team. Planning & implementation.

Procedure Development. Personnel training and qualification.

Lessons learned.


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SONGS Controls upgrade

The Feed Water Control and TurbineControl systems at SONGS werebecoming unreliable due to component

aging and replacement parts weredifficult to procure. An Ovation DCS was selected replace

the existing Feed Water Control, MainTurbine Control and Turbine Trip

systems.


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SONGS FWCS and TCS

Upgrade Install an Ovation network backbone and

Ovation Operator and Server Drops. Feed Water Control System: Remove the legacy control cabinets. Install Ovation cabinets (controller and extended

I/O). Rework control boards to remove legacy control

stations and indication.

Install touch screens and SLIMS. Modify the existing plant instruments to provideisolated redundant inputs to the DCS.


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SONGS FWCS and TCS

Upgrade Turbine Control System.

Gut existing cabinets (5). Install Ovation Controllers and I/O in

three of the cabinets. install Fan-Out network hardware for UnitDCS in one cabinet.

Perform Control Room modifications.


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The SONGS DCS Team

The scope of this control upgrade was such

that SONGS managers determined that keyplayers and end users should be involved inall phases of the project, from concept toinstallation.

Previous projects had suffered from theeffects of Silos. Management thought thata team structure would help to bringtogether isolated groups and provide for a

more efficient high quality project.


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The SONGS DCS Team

The SONGS DCS Team consisted ofrepresentatives of the followinggroups:

Design Engineering. Maintenance Engineering. Procurement. Maintenance. Operations.

Vendor (Westinghouse Nuclear).


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The SONGS DCS Team The SONGS DCS Team consisted of

representatives of the following groups:

Project Management and Engineering Services.(Construction).

Plant Management.

Maintenance. Computer Engineering. Training.

DCS Team members served as the lead fortheir respective group in project activities.


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Maintenance DCS Team

Team mission: Provide error free implementation of the

upgrade.

Ensure that I&C personnel are qualified toinstall, operate and maintain the DCSequipment.

Perform all support operations for theproject; planning, proceduredevelopment, document review andengineering support.


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Team mission: Perform all on and offsite testing. Provide timely feedback to maintenance

management. Provide for a transparent product. Provide clear and open communications

with all other groups in the SONGS DCSTeam.

Provide a core group to allow for futuregrowth of maintenance personnel.


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Members: Supervisor (Team Lead). 6 I&C Technicians

4 assigned for full time from outage M-6. 2 assigned part time.

Procedure writer. Part time assignment to mentor the

Maintenance Team in proceduredevelopment.


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Maintenance Team

Challenges First time evolution.

No experience in performing an upgradeof this scale.

Industry experience was very limited(nuclear). The Technicians were not planners or

procedure writers. We had to learn as we went on everything.


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Maintenance Team

Challenges Team approach was unfamiliar to the

Maintenance Team. True team effort everyone supports

everyone else. Most decisions to be made at the lowestpossible level.

First time not being told what & how todo it.

Members given authority commensuratewith responsibilities.


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Maintenance Team

Challenges High Risk Evolution.

New team was given broad responsibilityand authority, failure to meet objectivescould have lead to project delay.

SONGS Maintenance management tookthe risk of this new approach. High work load on the team, coupled with

inexperience was not indicative ofsuccess.


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Maintenance Team

Challenges Why did SONGS managers take this

risk? Previous upgrades to plant equipment

were performed by a Construction grouputilizing contract personnel. In general these tasks were performed in a

high quality manner. The expertise gained in system installationleft site with the contractors.


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Maintenance Team


risk? In general training and procedure

development were not considered corerequirements to project completion. Many systems were still lacking

procedures and training long after startup.


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Maintenance Team


risk? A project with the scope and significance

of the DCS upgrade, would require thatorganic SONGS personnel, have theskills and knowledge to maintain the

systems.


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Maintenance Team

Challenges SONGS Management determined that

SONGS organic personnel performingthe upgrade would:

Provide a skilled core group of maintenancepersonnel to maintain the system afterstartup.

Provide for Integrated implementation.


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Maintenance Team


risk? SONGS Management determined that

SONGS organic personnel performing theupgrade would provide for integration of:

Training.

Qualification. Procedures. Preventative Maintenance Programs.


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Lessons Learned.

Communicate. Ovation Certification of key players

early in the program leads to success.

An offline system is essential. Put Point IDs for I/O on Loop Drawings

/ Wiring Diagrams, this provides a tiebetween Ovation and the plant. Talk to those who have done it before.


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Lessons Learned.

Configuration Control is job 1. Your Vendor is your friend (if not, well I

am not going there).

Keep responsibility commensuratewith authority.

Establish Roles and Responsibilitiesearly and do not be afraid to changethem if necessary.


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Lessons Learned.

Cyber-Security is important. Reallyimportant. Open communications withthe CS group is essential.

Use the Factory Acceptance TestFree Form or Customer testing. Build Human Performance into

procedures.


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Contact

Tim Isaacs

I&C Supervisor [email protected] 949-368-7937

Mike Root Maintenance Engineering [email protected]

Cheryl Atooli Design Engineering

[email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Q and A

a road to successful integrated dcs upgrades

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