steps towards a large -scale i&c modernization at the paks ... · power uprating toto 108%...

Steps towards a largeSteps towards a large--scale scale I&C modernization at the I&C modernization at the PaksPaks NPP NPP

to support the planned to support the planned plant service time extensionplant service time extensionT.T. TTúúri, Bri, B.. KaticsKatics, , JJ.. VVééghgh, , EE. . HollHollóó, I. Varga, I. Varga

ee--mail: mail: [email protected]@sunserv.kfki.hu

IAEA IAEA -- Second International Symposium on Second International Symposium on Nuclear Power Plant Life Management (Nuclear Power Plant Life Management (PLiMPLiM))

ShanghaiShanghai,, China, 15China, 15--18 October18 October,, 20072007

PaksPaksNPPNPP

Paks NPP I&C modernization Paks NPP I&C modernization 22

Hungarian Academy of Sciences Hungarian Academy of Sciences KFKI Atomic Energy Research InstituteKFKI Atomic Energy Research Institute

Presentation Presentation overviewoverview�� Introduction to Introduction to PaksPaks NPPNPP�� Completed modernization projects: RPS,Completed modernization projects: RPS,plant computers, radiation monitoringplant computers, radiation monitoring�� I&C modifications for power I&C modifications for power upratinguprating::core monitoring, pressure controlcore monitoring, pressure control�� Preparations to replace traditional I&C Preparations to replace traditional I&C �� Scope, schedule of I&C reconstructionScope, schedule of I&C reconstruction



PaksPaks NPP in briefNPP in brief�� Four VVERFour VVER--440/213 units (1982440/213 units (1982--1987)1987)�� PresentPresent totaltotal capacity capacity = 1890 = 1890 MWeMWe�� ProductionProduction inin 2006 = 13.5 2006 = 13.5 TWhTWh ((≈≈37.6%)37.6%)�� SafetySafety enhancementsenhancements (1996(1996--2002)2002)�� PowerPower upratinguprating toto 108% (2006108% (2006--2009)2009)�� PlantPlant service service timetime extensionextension (30 (30 ⇒⇒ 50 y)50 y)



PaksPaks NPP in NPP in the Hungarian the Hungarian Transmission Transmission

Network Network ©© MAVIR MAVIR ZrtZrt..



Unit 2 = 100%Unit 2 = 100% Unit 1Unit 1 = = 108108%%Unit 4 = Unit 4 = 108%108% Unit 3 = 100%Unit 3 = 100%



Safety system refurbishmentSafety system refurbishment�� Motivation and functional improvements: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 1999Full reconstruction between 1999--20022002�� Result: tripleResult: triple--redundant, fully digital RPSredundant, fully digital RPS�� Tools: Tools: TelepermTeleperm XS, Space, XS, Space, ProfiSimProfiSim�� Extensive use of simulator for V&V testsExtensive use of simulator for V&V tests



Architecture Architecture of the new of the new

safety systemsafety system

ACTUATORCONTROL

Multiplexed optical link Physical separationProcess connection

SETSENSOR

Point - to - point individual wired link

DIV a DIV b

DIV a

DIV a DIV b DIV a DIV b

OR OR

EP2V3

OR

CONTROLLED PROCESS

C1

C3

PI C2

RED 1SETSENSORRED 2

SETSENSORRED 3

RPLRED 1

PO

IPL DIV b

C3

PI C2

PO

IPL

C1

DIV a

C1

C3

PI C2

PO

IPL DIV b

C3

PI C2

PO

IPL

C1

DIV a

C1

C3

PI C2

PO

IPL DIV b

C3

PI C2

PO

IPL

C1

ECCLC1 C2 C3

PO

DLSECCL

C1 C2 C3

PO

DLSECCL

C1 C2 C3

PO

DLS

ACTUATOR

Y

CONTROL

ACTUATORX

CONTROLACTUATOR

W

CONTROL

. . . ACTUATORS

. . . ACTUATORS

. . . ACTUATORS

. . . EP ACTUATORS

Point - to - point individual wired link ormultiplexed communication link

10YZ10YZ1 10YZ4 10YZ7

RPLRED 2

RPLRED 3

RED:DIV a, b:

RPL:IPL:

RedundancyDiverse "a", "b"

Reactor Protection LogicIntegrated Protection Logic



Animated RPS Animated RPS logic diagram as logic diagram as displayed in thedisplayed in thewindow of the window of the ProfiSimProfiSim tooltool



Process computer system (PCS) I.Process computer system (PCS) I.�� Most important Most important PaksPaks PCS functions: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 1998Full reconstruction between 1998--20032003�� Parallel work with RPS modernizationParallel work with RPS modernization�� Unit 1Unit 1--4, simulator + Plant Info Centre4, simulator + Plant Info Centre�� New items: CSF monitoring + EOP displayNew items: CSF monitoring + EOP display



Process computer system (PCS) II.Process computer system (PCS) II.�� Architecture of the unified PCS: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: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



Architecture of the new process computer at Unit 1Architecture of the new process computer at Unit 1



Main display Main display formatformat

of the new PCSof the new PCS



RPS state RPS state overview overview picturepicture



““IntegrityIntegrity””CSF pictureCSF picture



Radiation monitoring systemsRadiation monitoring systems�� 11stst step: environmental monitoring systemstep: environmental monitoring system� Full system reconstruction between 2000-2004� 9 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

�� 22ndnd step: internal radiation monitoringstep: internal radiation monitoring� Full system reconstruction between 2006-2010� New dosimetry control room with large display panel� Scada components with limited soft-control



M

GP

/ BIT

T Radiation detectors Dosimetry control room

Operator workstations

Operator workstations

Air sampling valves

Unit 3 process computer room

Unit 2 process computer room

Protected control post (bunker)

Printers

Scada server

Scada server

Scada server

Printers Scada server

Scada server

Scada server

Scada server

Scada server

Printers

Data

con

cent

rato

r

Plan

t ind

ustri

al L

AN

Cont

rol P

LC

Containment doors

Cont

rol

PLC

Rem

ote

I/O

Rem

ote

I/O

Dual

I&

C Fi

eld

LAN

Large Panel Display

Printers

WEB server

To remote workstations

Architecture Architecture of the newof the newinternal internal radiation radiation monitoring monitoring systemsystem



PowerPower upratinguprating projectproject�� Most important plant modifications: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



VERONA core surveillance systemVERONA core surveillance system�� Main objectives and improvementsMain 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 2005Full reconstruction between 2005--20082008�� Status: U1,3,4Status: U1,3,4 ++ simulatorsimulator = = O.K.O.K. U2U2 == 20082008



Architecture Architecture of the new of the new VERONA VERONA systemsystem



Main display Main display format of the format of the new systemnew system



History of History of reaching first reaching first 104% then 104% then

108% power at 108% power at Unit 4 (2006)Unit 4 (2006)



Primary pressure controllerPrimary pressure controller�� Problems with old 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 Solution = installation of a new controller:new controller:� Built from functionally + spatially distributed PLCs� Industrial Ethernet for communication + field buses� Continuous analogue control (122.75-123.25 bar)� Highly stable primary pressure control ensured



Scheme of Scheme of the new the new pressure pressure controllercontroller



Characteristic of Characteristic of the new controllerthe new controller

p [ bar ] 125 126 127 128 129 130 131 132 180 360 540 720 900 1080 1260 1440 1620 P [ kW ]

123 122 121 120 119 5 10 15 20 25

q be [ t/h ]

I. II.

III. IV.

V.

YP11 S401

YP11 S402

YP11 S403

YP11S404

Electrical heaters

Injection valves



View of View of the main the main controllercontroller



Comparison of the Comparison of the behaviourbehaviour of the old an new pressure controllersof the old an new pressure controllers

OldOld

NewNew



Present I&C situationPresent I&C situation�� Safety I&C systems:Safety I&C systems:� Fully reconstructed, present state is satisfactory

�� Traditional Traditional (non(non--safety)safety) I&C systems:I&C systems:� Approaching their expected service time� Modernization is needed for service time extension

�� Plant information & supervision systems:Plant information & supervision systems:� Most of them was (or will be) reconstructed � Their present state is (or will be) satisfactory



Preparations and studiesPreparations and studies�� Development of the I&C functional modelDevelopment 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 = I&C pilot project = ““tasting the puddingtasting 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



Scope and schedule of the I&C worksScope and schedule of the I&C works�� PaksPaks--specific guide specific guide (based on IEC TR 62096)(based on IEC TR 62096)�� Major steps identified for the Major steps identified for the PaksPaks case:case:� Establishment of the I&C project framework� Preparative activity (e.g. requirements specification)� Design phase � Manufacturing phase � Installation phase

�� Proposed tProposed time schedule ime schedule � Preparations and project launch: between 2007-2011� Site installations at the units: between 2012-2015



PCS M

IY Safety

M/S_PLC

S_PLC ACM

RPS Y M/S_PLC

S_PLC ACM

RPS X M/S_PLC

S_PLC ACM

RPS W M/S_PLC

S_PLC ACM

M/S_PLC

S_PLC ACM

MSI MCR GW B

SMS

MSI ECR

OP

GW A

OP PCS ESMS OP OPGW M GW E

IX Safety IW Safety IA Reactor

IT Primary circuitIR Secondary circuit

IS TurbineIG GeneratorIJ Electrical

IU External

Plant network

LAN ECR

LAN MCR

I LAN Y I LAN X I LAN W I LAN A I LAN U

MCR ECR

ACM

ACM

ACM

Safety Class 2Safety Class 3 SINEC L2

Industrial Ethernet (twisted pair)

SINEC H1Industrial Ethernet (optical)

Wired connection

Gigabit Ethernet (optical)Safety Class 4

ECR: Emergency CRMCR: Main Control RoomGW: RPS gateway computer

PCS: Plant Computer SystemOP: Operator workstationSMS: Safety Monitoring System MSI: Monitoring & Service Interface

Scheme of the new process control systemScheme of the new process control system

steps towards a large -scale i&c modernization at the paks ... · power uprating toto 108%...

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