Applications & Benefits of Engineering Simulatorsscs.org/wp-content/uploads/2018/01/L3M-PPS2018... · 2018-09-20 · DCS (Siemens SPPA-T3000) • Plant simulation attached to actual

Applications & Benefits ofEngineering Simulators

17 January 2018

Michael ChatlaniVincent Gagnon

2018 Power Plant Simulation Conference (PowerPlantSim’18)

Topics

• Introduction

• Engineering Simulators

– Applications

– L3 MAPPS Enabling Simulation Technologies

– Main Challenges & Solutions

– Benefits

• Examples of Engineering Simulators

• Conclusions

PPS 2018 © 2018 L3 MAPPS. All rights reserved. 2

Introduction

Operator Training Simulators: Mission Accomplished!

L3 MAPPS has been providing Nuclear Power Plant Operator Training Simulators since 1973


Operator Training vs. Engineering Simulator

• Engineering Simulator

– Desktop-based with virtual (soft) panels and operator HMI

– Focused on other applications to support plant activities


• Operator Training Simulator

– Full main control room hardware replica

– Focused on plant operator training

Same Plant FunctionalitySource: AREVA Source: AREVA

Why consider Engineering Simulators?

• Operator Training Simulators Reality

– Large investment for utilities and other organizations

– Utilized mainly to train plant operators to prevent human performance errors

– Current simulator modeling and physical fidelity and realism are well suited for engineering purposes

– Technology is such that computing power is no longer a constraint

• Why not leverage the Operator Training Simulators investments for other purposes?

• Why

– Risk a plant startup delay due to engineering design issues?

– Risk an unplanned trip due to poor control room human factors engineering?

– Test systems in open loop when they can be tested in closed loop with realistic plant response feedback?

• Engineering simulators are made possible for Nuclear New Builds as well as Existing Nuclear Power Plants


Engineering Simulators

Applications

• Plant Design Verification and Validation (V&V) – Nuclear New Builds– I&C Controls (Closed Loop)– DCS & Plant Process Computer HMI (Operator Displays)– Alarms– System Process (System Design and Equipment Characteristics)

• Plant Modifications V&V – Existing Nuclear Power Plants• Main Control Room Human Factors Engineering/Research• Safety Assessment Studies (LOCA, SGTR, Inadvertent Dilution, PSA, etc.) • Training

– Regulator– Plant Personnel (Engineers, ERO, Management, etc.)

• Plant Procedures (Operating, Maintenance, Commissioning, etc.) Development, V&V and Dry-Run• Severe Accident & SAMGs Analysis• Licensing Support• Simulator V&V• etc.


Example: Early Identification of Plant Design Issues

• Engineering Simulators can and should be used to assist in plant/DCS engineering and other applications

• L3 MAPPS NNB simulator developments have contributed to the early identification (and resolution) of 1,000s of plant design issues

• Example of distribution of discrepancies on one NNB simulator project:

26% Process toDCS Interface

12% Non-safetyDCS Calibration

45% Non-safety DCS

5%3%

Modeling andCalibration

Data

9% Safety DCS


Main Challenges

• Plant design changes constantly

– Especially true for Nuclear New Builds/DCS

• How to easily identify what needs to be modified on the simulator when the plant data changes?

• Engineering design change process is slow

• Most Operator Training Simulators are over-utilized not leaving enough time for activities not related to operator training

• Plant departments (other than Training and Operations) do not know about the potential, capabilities and benefits of simulation


Solutions

• Simulation models match one-to-one plant design documents/drawings

• Graphical models and real-time graphics allow for prototyping, quick changes and immediate feedback

• Automated process to update the simulator DCS controls and HMI (DCS Translation Process)

• Strong configuration control and management tools designed for graphical simulation tools

• Educate plant personnel on possible simulation applications


L3 MAPPS Enabling Simulation Technologies

• Real-Time Graphical High-Fidelity Models

• Object-Oriented & Data Import Capability

• Easy to Use Modeling Tools


• Real-Time Operator HMI Displays

• Object-Oriented & Data Import Capability

• Easy to Use HMI Simulation Tools

• Versatile I/O System Solution

– Closed Loop Testing Capability

• Easy to Use I/O Diagnostics & Monitoring Tools

• Real-Time Graphics

– Soft Panels

– Active Schematics

• Object-Oriented

• Easy to Use Graphical Tools

Simulation vs. Plant Design: One-to-One

Plant Documents Repository (SharePoint)

Plant System Models (Orchid®)

Plant Documents synchronized with Simulation ModelsSimulation Models synchronized with Plant Documents

Containment Reactor RCS BOP Electrical I&C


DCS Translation Process

HMI Pages

Plant Database

Plant DCS Input Files

Controls

HMI Pages

SimulatorDatabase

Simulator Files

Orchid®Controls

Translator Tool


Configuration Control & Management

Plant Data• Plant design data can be referenced and tracked in Orchid® Modeling

Environment at schematic [system] or library object [component] level

• Live connection with SharePoint

– Easy navigation between plant design data and modeling schematics/objects

• Plant design data tracking can provide a snapshot of where plant data is used and which schematics/objects are affected by data updates


Configuration Control & Management

• Schematics, libraries and files versioning

• Version rollback capabilities

• Visual comparison feature for different versions of

– Workspaces

– Configurations

– Schematics

– Libraries

– Files


Benefits

• Quantitative

– Protect the health and safety of the public and plant workers (e.g. injury, radiation exposure, death, etc.)

– Prevent equipment failure and damage (e.g. turbine, main feedwater pump, etc.)

Depending on equipment, could result in millions of dollars in repairs plus loss of generation…

– Prevent unplanned plant shutdowns and extended plant outages

Direct costs associated with refueling outages can exceed $800,000 USD per day

Loss of generation can exceed $500,000 USD per day

[source: Oliver Wyman research (global management consulting firm) as reported by Power Engineering in 2009]

– Early identification and correction of deficiencies is significantly less costly than during commissioning

– Return on investment of a relatively inexpensive Engineering Simulator can be significant


Benefits

• Non-Quantitative

– Inherent (built-in) simulation features such as speedup/slowdown, automated testing, charts, data collection, etc.

– Enhance quality/user friendliness of plant engineering products

– Better acceptance of plant modifications by operators

– Enhance quality of Operator Training Simulators

Testing and validation beyond standard testing

– Increase credibility with regulators, outside organizations and peers (NRC, INPO, WANO, other utilities, etc.)

Industry best practices

– Company public opinion by preventing a plant event

– Same technology used for Operator Training and Engineering Simulators


Examples of Engineering Simulators

Example: SNERDI CAP 1400 Engineering Design Analyzer (NNB)

• Shanghai Nuclear Engineering Research and Design Institute (SNERDI)

• CAP1400 Engineering Design Analyzer

• Used to

Support CAP1400 engineering design activities

Develop interfaces with third-party applications

“SNERDI put considerable effort into identifying a technology that would be well-suited to developing theEngineering Design Analyzer. We selected L3’s Orchid® to help us meet our goals and we look forward to L3’scollaboration as we move into the development phase.”

Gu Guoxing, vice president of SNERDIPPS 2018 © 2018 L3 MAPPS. All rights reserved. 20

Example: Olkiluoto 3 (EPR) Engineering Simulators (NNB)

• AREVA• EPR Design V&V (multiple copies)

• Used for

Digital I&C design V&V

o Interfaces

o I&C functions

o Normal operation

o Defense in depth concept

o Operating displays

Systems design V&V

Test plant operating procedures

Dry-run commissioning proceduresPPS 2018 © 2018 L3 MAPPS. All rights reserved. 21

Source: AREVA

Example: Simulator for Human Factors Research

• Idaho National Laboratory (INL)• Human Systems Simulation Lab (HSSL)

• Used to

Test emerging technologies for their application in control rooms

Prototype HMI displays and control room variations with operator-in-the-loop

Source: INL



• SNC-Lavalin Nuclear• Enhanced CANDU 6 (EC6) Engineering Simulator

• Used to

Develop and validate the new EC6 main control room

Design and test programmable electronic systems (PES) and human-system interfaces

Source: SNC-Lavalin Nuclear



• Center for Advanced Engineering and Research -Center for Safe and Secure Nuclear Energy

• Advanced Configurable Main Control Room Simulator

• Used to perform critical experiments in the U.S. for

Alarm systems

Control room design

Display navigation

Development of human performance measures


Example: Simulator for Safety Studies

• AREVA

• L3 MAPPS simulation integrated with CATHARE (French advanced calculation code) used to study the behavior of pressurized water reactors in accident conditions

• Used to perform

Plant engineering and emergency response training

Operating procedures analysis and improvement

System design modifications

Preliminary safety analysis

Source: AREVA


Example: Simulator for Plant Modifications/Operator Confidence

• Ameren Missouri

• Operator replacing analog feedwater controls with DCS (Siemens SPPA-T3000)

• Plant simulation attached to actual feedwatercontrol cubicles to exercise the new DCS before DCS implemented on actual plant

• Combined system flagged numerous design issues which Ameren Missouri used to mitigate unintended problems with the DCS designer

I/O ModulesSimulation Computer

HMISPPA T3000


Example: Simulator for TSO

• Institut de Radioprotection et de Sureté Nucléaire (IRSN): TSO to French safety authority (ASN)

• SOFIA: Simulator for Observation of Functioning during Incidents and Accidents

• Used for

Engineer training (from beginners to experts) (ASN, CEA, IRSN)

Preparation of emergency response exercises

Studies in support of safety evaluations

System design modifications

Preliminary Safety Analysis (EOPs, Nuclear Safety, Incidents & Events analysis, Post-Fukushima analysis, PSA, …)


Example: Simulator for Nuclear Regulator

• National Regulation Authority

• Severe Accident Simulator (PWR)

• Developed in cooperation with Westinghouse for NRA

• Supports normal operations, transient events, Design Basis Accidents, Beyond Design Basis Accidents, Severe Accidents and actions to be taken by operators who experience the incidents

• Used to

Train regulatory body personnel


Conclusions

Conclusions

• Operator Training Simulators have been successfully delivered and utilized for decades to train plant operators

• Engineering Simulators can be utilized for a variety of other applications

• L3 MAPPS offers robust and mature simulation tools for both Operator Training Simulators and Engineering Simulators

• Engineering Simulators offer quantifiable and other benefits

• L3 MAPPS has extensive experience in delivering Engineering Simulators for different applications for Nuclear New Builds and Existing Nuclear Power Plants


With the benefits of plant safety, personnel safety and costs savings, leveraging the Operator Training Simulator investment into a low-cost Engineering Simulator is a wise investment

Engineering Simulator

Conclusions


Plant initial costs: in the billions of $Plant operating and maintenance costs: in the 100s of millions $ per year for a fleet of nuclear reactors[source: EDF Energy]

Plant

Simulator initial costs: in the millions of $

Operator Training Simulator

Thank YouL3 MAPPS

8565 Côte-de-LiesseMontréal, Québec, Canada

H4T 1G5

Tel: +1 (514) 787-4999 Fax: +1 (514) 788-1442

Web: www.L3T.com/MAPPSLinkedIn: L3 MAPPS

L3 MAPPS8565 Côte-de-Liesse

Montréal, Québec, CanadaH4T 1G5

Tel: +1 (514) 787-4999 Fax: +1 (514) 788-1442

Web: www.L3T.com/MAPPSLinkedIn: L3 MAPPS

2018 Power Plant Simulation Conference (PowerPlantSim’18)