Generation

1
Comprehensive renewal of IC at Loviisa Nuclear
Power Plant
Fortum Power and Heat / Loviisa Power Plant Ulf
Linden

• IAEA Technical Meeting on the Impact of Digital
  Instrumentationand Control Technologies on the
  Operation and Licensing of Nuclear Power
  Plants3-6 November 2008 Beijing, China

2
Loviisa 1 and 2

• Reactor 510 MWe PWR (VVER-440 213)
• Plant owner Fortum Power and Heat
• Location Finland, Loviisa, 80 km east of
  Helsinki
• Commissioning Unit 1 1970 - 1977, Unit 2 1972 -
  1980
• High energy availability, short outages
• Originally installed IC systems
• Siemens hardwired solution for operational IC
  and ESFAS (Teleperm C, Simatic P)
• Russian solution for RPS (SUZ) and Control rod
  IC
• Renewal 2008
• part of RPS AREVA TXS
• waste water handling systems Siemens T2000

3
Load Factors of Loviisa Power Plant 1977-2007
4
Renewal of IC - Reasons for Renewal

• The nuclear power units Lo1 and Lo2 were
  commissioned in 1977 and 1980. Plant life time
  has been extended to at least 50 years.
• It is not possible to maintain the original IC
  systems to the end of the plant lifetime the
  systems are obsolete and problems with spare
  parts will increase.
• It is hard to get new engineers that have the
  knowledge in maintaining and repairing 30 years
  old electronic cards
• An IC renewal was required. The objective of the
  renewal is to ensure that the IC systems will
  not limit the safe and economical use of the
  plant during the remaining lifetime of plant.
• The units are now around the half of their
  lifetime. Now it is the right time to make the
  renewal while there is still a lot of lifetime
  left.

5
Milestones passed
6
Overall Scope of the Renewal
Control room
Renewed
Automation cabinets (Data acquisition and
logics)
Switchgear
Training simulator
Actuators
Field equipment
7
Time schedule
IC renewal time schedule

• STAGE 1 (pilot stage)
• Reactor shutdown, control rod sequence
• control and position indication
• automation systems of waste water handling

Commission
C
F
Lo1
Commission
C
F
Lo2
Commission
STAGE 2 Reactor protection and power
control Emergency diesel generator IC
F
C
Lo1
Commission
C
F
Lo2
Commission
C
F
STAGE 3 IC systems of the primary process
systems, ventilation systems
Lo1
Commission
C
F
Lo2
Commission
C
F
STAGE 4 (option) IC systems of the secondary
process and auxiliary systems
Lo1
Commission
C
F
Lo2
Contract with Supplier FAT Commission
C
F
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Main Principle of the Renewal

• The functions of the old automation remain.
• Single failure tolerance is built into the
  automation concept
• New cabinets are placed into new buildings that
  fulfill all new requirements (seismic req., EMC,
  etc.).
• Selection of a competent supplier, who has
  applicable products of reliable and proven
  technology that can be licensed in Finland
• Simulators shall be used effectively in the
  renewal process.

9
New IC buildings

• New buildings have been built for the IC
  cabinets.
• Due to the new buildings
• installations are easier.
• new requirements are met more easily
• better channel separation
• better EMC characteristics
• better seismic characteristics.

10
Control room

• Control room renewal
• Fortum is responsible for
• Functional design of control room and MMI
• Control room verification and validation (VV)
• Fortum will extensively use different kind of
  simulators in the design process
• Supplier is responsible for implementation
• and integration

• Existing control rooms
• Separate control rooms for both units
• Main control room (MCR
• Auxiliary control room (ACR)
• Ventilation control room (VCR
• Severe accident management (SAM) control room
  common for both units

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Loviisa 1 main control room before renewal of
IC for unit 1 stage 1)
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Loviisa 1 Control room stage 1
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Doing IC projects in stagesChallenges

• Doing the project in stages may be more
  economical than in one big outage, but
• Several stages have to go on in parallel
• More resources are needed
• Are the software and hardware version installed
  in the first stage still usable in later stages
  or will a long project cause ongoing updates?
• There will be several test fields and several
  factory acceptance tests is testing only in
  small parts enough?
• Can people involved commit themselves to be in
  the project for so many years?
• Persons may change on both the supplier and
  purchaser side

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Challenges Critical Path

• Installation and commissioning performed in
  outages
• Short time for work
• A problem during installation or commissioning
  can prolong the outage in an unacceptable way
• A delay in one stage can move the schedule for
  other stages
• Very challenging to do the modifications in the
  control room in stages
• May need temporary controls during outages for
  critical systems and components
• Challenging to do the modifications in the
  simulator
• The training of control room operators must start
  6 - 12 months before commissioning,

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Some lessons learned

• Good Requirement Specifications are very
  important
• tools for tracing requirements needed
• Collection of initial data from an old plant
• huge amount, in which form and in which language
  shall it be delivered
• can the engineers of today read 30 year old hand
  written circuit diagrams
• Resources
• most experienced people on the plant needed
• not the only project for the supplier
• Supplier's organisation
• the supplier must have a project organisation on
  the site that closely works together with plant
  people
• Authorities
• national nuclear guidelines must be taken into
  account in licensing

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Success factors

• Fortum had a good knowledge of the new system
• Comprehensive training of people, participating
  in the testfield, installation and commissioning
• Large pre-installations were done before outage
• Simulated assisted testing
• Automation systems must be tested before
  installation
• Like virtual commissioning, dynamic tests can be
  run
• Errors from faulty initial data could also be
  found

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Summary

• Two Nuclear Power Plant Units
• Four modernization stages/unit between 2008 and
  2014
• Two main suppliers
• New IC buildings enable pre-installations
• Installation and commissioning in normal
  refueling outages
• Modifications made also to the control room and
  full scope training simulator
• Successful commissioning in 2008 of stage 1.