Experience of digital I

1
Experience of digital IC implementation at
Russian NPPs
RUSSIAN RESEARCH CENTRE KURCHATOV INSTITUTE
(Based on materials presented by Dr. Sivokon (RRC
KI), Dr. Dunaev and Dr. Bozhenkov (VNIIAES) at
the IAEA and Rosenergoatom meetings in 2005-2006)
Dr. Vladimir Sivokon

• The EPRI-IAEA Joint Workshop on Instrumentation
  and Control Systems in Nuclear Power Plants
  Vienna, 3-6 October 2006

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Contents

• Introduction development of Russian NPPs
• Main Achievements and Projects of digital IC
  design and implementation at Russian NPPs
• New IC of Kalinin-3 (WWER-1000) the most
  interesting example of digital IC implementation
  at Russian NPPs
• Experience and results of trial operation of
  digital IC at Kalinin-3
• Tasks of further development
• Summary

3
Geography of Russian Nuclear Power Plants
4
New NPP Units Commissioning and Plans of
Construction (confirmed and announced)

• In December 2004 WWER-1000 Unit (Kalinin-3) was
  started up with the new programmable IC systems
• Volgodonsk-2 (WWER-1000) start-up is scheduled
  for 2008
• Kalinin-4 (WWER-1000) start-up is scheduled for
  2011
• Balakovo-5 (WWER-1000) start-up is scheduled for
  2011
• In September 2006, following the State policy, a
  new Head of Rosenergoatom Utility (Dr. Sergey
  Obozov) announced that in 2009 the Utility will
  simultaneously construct 9 nuclear Units with a
  plan of commissioning 2-3 Units per year in the
  future (besides listed above plants at Beloyarsk,
  Leningrad, Novovoronezh NPPs)

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Comments to the Plans of NPPs Construction

• Obviously, such ambitious plans of commissioning
  of so many nuclear Units for some specialists
  seem to be quite doubtful
• The question is Are these plans realistic at all
  under existing conditions and infrastructure?
• Any specialist has his own opinion and answer on
  this question
• To approach to the realistic answer it is useful
  to refer to the experience of nuclear Units
  commissioning in the former Soviet Union, see the
  next slide

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Commissioning of NPP Units in Countries of Former
USSR
Number of Units
5
Kmelnitsky NPP, Unit 2
4
Rovno NPP, Unit 4
Kalinin NPP, Unit 3
3
Balakovo NPP Unit 4
Zaporozhe NPP Unit 6
2
Volgodonsk NPP Unit 1
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0
1971
1972
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1989
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2004
2005
Year
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Current Age of Russian NPP Units in Operation
(2006)IC modernisation is executed at many
Units
8
Capacity Factor of Russian NPPs
9
Trend of the Events at Russian NPPs
IAEA ASSET missions started
New reporting criteria
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Main Achievements in Digital IC Design and
Implementation in 2002-2006

• Commissioning new computerized IC for Kalinin
  NPP (Unit-3), implementation of soft control for
  WWER-1000 for the first time in Russia
• New programmable controllers TPTS (based on
  Teleperm MEA licensed by VNIIA Institute,
  Moscow) and KPTS-PN (Physpribor factory,
  Moscow) of safety classes A and B (IEC 1226) have
  been designed and implemented
• Industrial servers of safety class B (IEC 1226)
  were designed and qualified for PCS upper level
  of WWERs
• New digital reactor control and protection system
  was designed by NIKIET (RD Institute of Power
  Engineering, Moscow) for RBMKs and commissioned
  at Kursk and Leningrad NPPs

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Main Achievements in Digital IC Design and
Implementation in 2002-2006 (cont.)

• Implementation at the nuclear power plants
  intellectual pressure transmitters calibrated
  on-line
  (Metran, Chelyabinsk)
• New full scope simulator with VR-based elements
  was developed and implemented at Leningrad NPP
  (IFE-Halden, RRC KI and LNPP)
• New computerized complex of HMI optimization for
  MCR was designed and implemented at LNPP (DSS,
  RRC KI and LNPP, in the framework of TACIS
  Project 2005-2006)

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Leningrad NPP Simulators Get Virtual Reality

• RRC KI and IFE (Halden, Norway) developed and
  implemented Refuelling Machine Simulator (RMS-VR)
• RMS-VR is on-line connected with RBMK full scope
  simulator for the operators shift team work

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Main Projects of Digital IC Implementation

• Project of fully computerized IC with
  programmable controllers in safety systems and
  usage of soft control at WWER-1000 MCR for the
  first time in Russia (Kalinin-3)
• NIKIETs Project of new reactor control and
  protection system for RBMK based on programmable
  controllers (Kursk-1,2, Leningrad-1,2). The
  Project was recently extended for ESFAS
• Project of gradual replacement of UKTS control
  devices (WWER-1000) by functional analogues
  designed on the basis of programmable
  controllers KPTS-PN (Balakovo NPP)
• Project of implementation of Metran pressure
  transmitters
• Project of modernization of RPS at pilot
  WWER-1000 (Novovoronezh NPP) by means of
  programmable controllers of Schneider-DSS (TACIS
  Project was started and cancelled)

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New APCS Developed for Kalinin NPP Unit 3

• The following types of control are used in MCR

• Automatic control (of function groups, interlocks
  and protections and so on) implemented at low
  level hardware in compliance with WWER-1000
  design
• Display soft control remote control from SVBU
  workstations monitors through low level system
  (TPTS)
• Remote control from MCR panels hardwired directly
  to low-level system
• Remote control through plant intercommunication
  and local consoles by shift personnel
• Supervision control by Shift Supervisor for
  coordination and organization of shift work

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Control Conception of Kalinin NPP Unit 3
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Layout of the MCR of Kalinin NPP Unit 3 as Was
Originally Designed by NIIIS Institute
(N-Novgorod)
17
View of Kalinin NPP Unit 3 MCR During Preparation
to Commissioning (February 2004)
18
View of Kalinin-3 MCR as of Dec. 2004(large
screens of common view are added)
19
Kalinin-3 Connection to Grid with Russian
President Participation (16 Dec. 2004)
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Kalinin-3 Safety Panels (MCR Fragment)
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Video-fragment of KNPP-3 APCS Workstation
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Diagram and Views of Low Level Hardware (TPTS)
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Kalinin NPP Unit 3 APCS Response Times
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Structure of Kalinin NPP Unit 3 SVBU (Upper Level
of APCS)
The SVBU System consists of

• 6 Alpha Servers ES45
• 2 redundant reactor island servers
• 2 redundant turbine island servers
• 2 redundant information servers
• 25 workstations (2 of them for large panels of
  common view)
• Low lever IC subsystems and means
• 62 TPTS cabinet units of programmable controllers
  (manufactured in Russia by VNIIA /Moscow/ under
  the Siemens license similar to TELEPERM ME)
• 6 additional IC subsystems (so called special)
• 2 IC subsystems were connected later

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Kalinin NPP Unit 3 SVBU Software Structure
26
Comparison of Number of Analogue Discrete
Signals Processed by KNPP-3 APCS andOld PCS
Titan
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Results of IC Trial Operation APCS Upper Level

• Real characteristics of the system correspond to
  the Technical Specification in steady and
  transient conditions
• Safe and reliable operation of the system with
  technological equipment and subsystems are
  confirmed in steady and transient conditions
• All planned tests have been conducted
  successfully
• The system provided complex testing the
  technologic equipment at rated power and
  continuous keeping technological parameters
  within the operational limits and conditions

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Experimental Data of Analogue Digital Signals
(reactor island) Processing by KNPP-3 APCS at
Black-out Test
Number of signals per second
Analogue
Discrete
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New Quality of Kalinin-3 IC Enhanced
Diagnostics

• Nowadays the following information is available
  at APCS Upper Level

• Tasks condition at the workstations
• Communication with servers via main and stand-by
  nets
• Tasks (processes) condition at the master-server
• Tasks (processes) condition at the slave-server
• Condition of the driver responsible for
  communication with TPTS
• Condition of the driver responsible for
  communication with special subsystems
• Condition of APCS Lower Lever (TPTS)
• Diagnostic information on each TPTS cabinet and
  its modules (each channel)

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Results of IC Trial Operation Problems at APCS
Upper Level

• Works on long-term archives were not finished
• Non-stable operation of communication drivers of
  TPTS and special subsystems was sometimes
  monitored (resulted in servers switching over)
• Works on presentation of diagnostic information
  on conditions of technical means of APCS Upper
  Level were not finished
• Works on implementation of function
  Configuration to control changes in the data
  base were not finished
• System change over to winter time caused
  questions
• Lists of signals for exchange between main
  servers and those ones intended for information
  server were not fixed

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Positive Results and Weaknesses Revealed During
Programmable Controllers (TPTS) Implementation at
APCS Lower Level

• Achievements

• Increase of reliability of the safety system
  (ESFAS)
• Increase of availability factor of safety system
• Procedures of implementation of changes became
  easier
• Decrease of equipment amount
• Extended possibilities for monitoring and control
  of the technological processes

Weaknesses

• Lack of electrical decoupling and fiber optic
• Lack of filtering of diagnostic signals going to
  APCS Up. Level
• Low response time for some application

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Results of IC Trial Operation Reactor Control
System

• New Reactor Control System implemented at
  Kalinin-3 is designed on the basis of
  microprocessors.
• Microprocessors are used in the Control System of
  Control Rods Groups, Reactor Power Automatic
  Controller (ARM) and information-diagnostic
  service system.
• Achievements
• Enhanced reliability
• Increased level and depth of diagnostics

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Results of IC Trial Operation Metran Pressure
Transmitters

• For the first time at Russian NPPs, at Kalinin-3
  the Metran-22 AC MP pressure transmitters based
  on microprocessors have been implemented
• These pressure transmitters have fast response
  time, high accuracy and built-in diagnostics
• However, fast response time of Metran-22 AC MP
  beside positive results produced a problem with
  filtering of noise at some technological signals
• Adaptive filter of TPTS solved this problem for
  many signals but not for all of them (pending
  problem for some flow meters)

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Pending Problems of Kalinin-3 IC in General

• At the end of IC trial operation at Kalinin-3
  the following pending problems existed

• Black-box monitoring and archive system was not
  implemented yet
• Functional analysis of MCR and ECR was not fully
  completed
• Final version of HMI analysis report was not ready

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Failures Revealed Eliminated At Trial Operation
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Tasks of Further Development

• Identification of new ratio between automated and
  manual control for the next generation of NPPs
  (increasing level of automation)
• Unification of the IC technical means within
  each safety class
• Use of new technologies and technical means, for
  example new POSAFE-Q PLC (KNICS, Republic of
  Korea) in safety systems
• Comparison and harmonization of Russian and
  international requirements on design and
  qualification of digital IC systems important to
  safety
• Human Machine Interface enhancement for new
  generation of NPPs

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Summary
In general, the process of implementation of
digital IC at Russian NPPs was assessed as quite
successful
Thank you very much for your attention!