Effective Control of Instrumentation and Control (I&C ...Project Management Engineers (Project office) Responsible for managing project activities such as documentation, material management,

Effective Control of Effective Control of Instrumentation and Instrumentation and Control (I&C) Control (I&C) Modernization, Modernization,

Presented by:Presented by:

ZakiaZakia RabbaniRabbaniDeputy Chief Engineer, Deputy Chief Engineer, Karachi Nuclear Power Plant, PakistanKarachi Nuclear Power Plant, Pakistan

Methods and ToolsMethods and Tools

Presented at 2Presented at 2ndnd International Symposium on International Symposium on Nuclear Power Life Management Organized by IAEA at Shanghai, ChiNuclear Power Life Management Organized by IAEA at Shanghai, Chinana

Oct, 2007Oct, 2007 IAEAIAEA--CNCN--155/073155/073 22

INTRODUCTIONINTRODUCTION

�� Karachi Nuclear Power Plant (KANUPP), located near Karachi Nuclear Power Plant (KANUPP), located near Arabian Sea coast, about 11 miles (17.7 km) west of Arabian Sea coast, about 11 miles (17.7 km) west of Karachi.Karachi.

�� Heavy water moderated and cooled, natural uranium Heavy water moderated and cooled, natural uranium fuelled CANDU type Reactor.fuelled CANDU type Reactor.

�� Horizontal pressure tubes. Horizontal pressure tubes. �� OnceOnce--through, onthrough, on--power bipower bi--directional fuelling.directional fuelling.�� Reactor shutdown by moderator dump.Reactor shutdown by moderator dump.�� Reactor building designed for total containment of any Reactor building designed for total containment of any pressure or activity resulting from a credible accident. pressure or activity resulting from a credible accident.

�� Gross plant output 137 MW(e) net output 125 MW(e).Gross plant output 137 MW(e) net output 125 MW(e).

SALIENT FEATURESSALIENT FEATURES


I&C at KANUPPI&C at KANUPPPrimary purpose of the I&C systems is to exercise proper Primary purpose of the I&C systems is to exercise proper control & provide automatic protection against unsafe and control & provide automatic protection against unsafe and improper reactor operation during steadyimproper reactor operation during steady--state and state and transient power operations & to provide initiating signals to transient power operations & to provide initiating signals to mitigate the consequences of faulted conditions. Digital mitigate the consequences of faulted conditions. Digital techniques are used for plant control, computation, and techniques are used for plant control, computation, and monitoring of parameters, annunciation & logging monitoring of parameters, annunciation & logging purposes & for fueling machine control.purposes & for fueling machine control.

Two digital computers are used for reactor power regulation Two digital computers are used for reactor power regulation & for individual channel monitoring, while two separate & for individual channel monitoring, while two separate computers used for fuelling machines.computers used for fuelling machines.

The remaining I&C can be subThe remaining I&C can be sub--divided into:divided into:�� Measurement LoopsMeasurement Loops�� Control LoopsControl Loops�� Reactor Protection LoopsReactor Protection Loops�� Engineered Safeguard LoopsEngineered Safeguard Loops


Need for I&C Modernization at KANUPPNeed for I&C Modernization at KANUPP�� The I&C used for KANUPP was based on the technology The I&C used for KANUPP was based on the technology of early sixties. During last four decades the of early sixties. During last four decades the advancement in technology has revolutionized the field. advancement in technology has revolutionized the field. Vendor support to the old pneumatic and / or discrete Vendor support to the old pneumatic and / or discrete electronic instrumentation had been discontinued and electronic instrumentation had been discontinued and due to lack of availability of spares it was not possible to due to lack of availability of spares it was not possible to maintain the equipment / system.maintain the equipment / system.

�� Due to technological advancements various features Due to technological advancements various features have been added in the new plants like SPDS, CPDS have been added in the new plants like SPDS, CPDS and Operator Information Systems, that enables the and Operator Information Systems, that enables the operator to take prompt action. The regulatory authority operator to take prompt action. The regulatory authority imposed such requirements on KANUPP also which imposed such requirements on KANUPP also which could not be met through old instrumentation.could not be met through old instrumentation.



I&C Modernization Project at KANUPPI&C Modernization Project at KANUPP�� PAEC had foresighted the need to perform I&C PAEC had foresighted the need to perform I&C modernization based on the above mentioned reasons modernization based on the above mentioned reasons and other rehabilitations projects for KANUPP to operate and other rehabilitations projects for KANUPP to operate the plant safely and efficiently. the plant safely and efficiently.

�� PAEC initiated the study for I&C modernization. After PAEC initiated the study for I&C modernization. After completion of the study, the bids were invited from completion of the study, the bids were invited from International suppliers. Overcoming the difficulties in International suppliers. Overcoming the difficulties in procurement of equipment at last the contract was procurement of equipment at last the contract was signed with the consortium of CEGELEC (France) and signed with the consortium of CEGELEC (France) and CEGELECCEGELEC--ACEC (Belgium). Under that contract the ACEC (Belgium). Under that contract the consortium only provided the equipment, while PAEC consortium only provided the equipment, while PAEC took the sole responsibility of engineering and took the sole responsibility of engineering and implementation.implementation.


Project ObjectivesProject ObjectivesThe Obsolescence / lack of vendor support was the major The Obsolescence / lack of vendor support was the major

problem while technological upproblem while technological up--gradation was the gradation was the benefit target with following prime objectives:benefit target with following prime objectives:

�� New equipment should improve the maintainability, New equipment should improve the maintainability, reliability, & availability of the systems resulting in reliability, & availability of the systems resulting in improvement the Plant performance.improvement the Plant performance.

�� New equipment be based on modern day technology New equipment be based on modern day technology so that plant may be kept operational without any so that plant may be kept operational without any problem for the remaining / extended life.problem for the remaining / extended life.

�� The replaced systems shall comply strictly to safety The replaced systems shall comply strictly to safety criteria specified in KANUPP Final Safety Analysis criteria specified in KANUPP Final Safety Analysis Report (KFSAR).Report (KFSAR).

�� Enhance the quality of information for the operator by Enhance the quality of information for the operator by addition of Process Information System & improvement addition of Process Information System & improvement in Manin Man--Machine Interface.Machine Interface.


Project TargetsProject Targets1.1. Replacement of :Replacement of :

a)a) Regulation Systems Computers,Regulation Systems Computers,b)b) Annunciation System,Annunciation System,c)c) Channel Temperature Monitoring System,Channel Temperature Monitoring System,d)d) Bearing Temperature Monitoring System, Bearing Temperature Monitoring System, e)e) Data Logging System Data Logging System f)f) 72 measurement loops, 72 measurement loops, g)g) 42 control loops, 42 control loops, h)h) 49 reactor protection loops,49 reactor protection loops,i)i) 15 engineered safeguard loops.15 engineered safeguard loops.


Project TargetsProject Targets2.2. Provision of a Process Information system to provide Provision of a Process Information system to provide

the operator information regarding plant status and the operator information regarding plant status and functioning of various equipment.functioning of various equipment.

3.3. Replacement of Fuel Handling computers.Replacement of Fuel Handling computers.

4.4. Replacement of Nuclear Instrumentation.Replacement of Nuclear Instrumentation.

5.5. Addition of Safety Parameter Display System (SPDS) Addition of Safety Parameter Display System (SPDS) and Critical Parameter Display System (CPDS). and Critical Parameter Display System (CPDS).


Effective Control of I&C ModernizationEffective Control of I&C ModernizationThe project objectives and targets are The project objectives and targets are achievable within the planned budget and achievable within the planned budget and scheduled time only if the project is effectively scheduled time only if the project is effectively controlled. The effective control is required to controlled. The effective control is required to achieve following objectives:achieve following objectives:1.1. I&C modernization evaluation performed timely and I&C modernization evaluation performed timely and

cover all necessary areas of modernization.cover all necessary areas of modernization.2.2. Proper planning for I&C modernization be carried Proper planning for I&C modernization be carried

out to ensure that the system, for which the work is out to ensure that the system, for which the work is being undertaken, remains available before and being undertaken, remains available before and after modernization and the system unavailability after modernization and the system unavailability time (if any) be as low as possible.time (if any) be as low as possible.



Effective Control of I&C ModernizationEffective Control of I&C Modernization3.3. System functionality meets or exceeds the one System functionality meets or exceeds the one

presently provided by the old system .presently provided by the old system .4.4. I&C modernization does not jeopardize the safety, I&C modernization does not jeopardize the safety,

reliability or availability of plant.reliability or availability of plant.5.5. I&C modernization be completed within planned I&C modernization be completed within planned

budget and scheduled time.budget and scheduled time.6.6. After modernization is carried out, the plant After modernization is carried out, the plant

personnel be trained to effectively use / maintain the personnel be trained to effectively use / maintain the new system / equipment and that sufficient support new system / equipment and that sufficient support is available to keep the plant operational for its life is available to keep the plant operational for its life (extended by 15 years beyond designed life).(extended by 15 years beyond designed life).


Tools and Methods used for Effective Tools and Methods used for Effective Control of I&C ModernizationControl of I&C Modernization

The methods and tools used for managing the modernization of The methods and tools used for managing the modernization of Instrumentation and Control at Karachi Nuclear Power Plant Instrumentation and Control at Karachi Nuclear Power Plant (KANUPP), resulting in successful achievement of the goals set b(KANUPP), resulting in successful achievement of the goals set by y the organization are:the organization are:

•• Project Organization (organization chart)Project Organization (organization chart)•• Identification of Problematic AreasIdentification of Problematic Areas•• Requirement specification for I&C Modernization at KANUPPRequirement specification for I&C Modernization at KANUPP•• Methodology to ensure plant safety / operability during installaMethodology to ensure plant safety / operability during installation /commissioningtion /commissioning•• Testing of new I&C systemTesting of new I&C system•• Quality AssuranceQuality Assurance•• Resource PlanningResource Planning•• Documentation controlDocumentation control•• Cost ControlCost Control•• Change ManagementChange Management•• Schedule Control Schedule Control •• Implementation PlanImplementation Plan•• Progress EvaluationProgress Evaluation•• Feedback collection and corrective Action ImplementationFeedback collection and corrective Action Implementation•• Questioning AttitudeQuestioning Attitude•• Consultation with relevant working groupConsultation with relevant working group




•• Project OrganizationProject OrganizationGuiding and supervising the project personnel is an Guiding and supervising the project personnel is an important and crucial aspect of project management important and crucial aspect of project management function and the Project organization specifies how to function and the Project organization specifies how to integrate the functions of personal involved in a project and integrate the functions of personal involved in a project and their responsibilities and level of authority.their responsibilities and level of authority.Project Organization for KANUPP for I&C Modernization:Project Organization for KANUPP for I&C Modernization:Project Manger (PM)Project Manger (PM)Responsible for overall implementation of project and Responsible for overall implementation of project and interface with Top PAEC management/ Regulatory interface with Top PAEC management/ Regulatory Authority / Vendors.Authority / Vendors.Project InProject In--charge (PI)charge (PI)Responsible for planning, integration and technical Responsible for planning, integration and technical coordination with design / installation / commissioning coordination with design / installation / commissioning teams.teams.



Senior Design Engineer (SDESenior Design Engineer (SDE)) Responsible for design Responsible for design activities for their concerned areas. The areas were:activities for their concerned areas. The areas were:•• Process control &InstrumentationProcess control &Instrumentation•• Computerized control and monitoring Computerized control and monitoring •• Annunciation systemAnnunciation system•• Data Acquisition system Data Acquisition system •• InfraInfra--structurestructure•• Support facilitySupport facility•• Process InformationProcess Information

Senior Installation Engineer (SIE) Senior Installation Engineer (SIE) Responsible for all Responsible for all installation related activities like Infrastructure,Wiring, installation related activities like Infrastructure,Wiring, Electronic room,control room modification & equipment Electronic room,control room modification & equipment placement etc.placement etc.


Senior Commissioning Engineers (SCE) Senior Commissioning Engineers (SCE) Responsible Responsible for commissioning related activities are up to quality for commissioning related activities are up to quality assurance principles and the functionality of the system assurance principles and the functionality of the system as per design requirement and plant safety is not as per design requirement and plant safety is not effectedeffected

Senior Quality Engineers (SQE) Senior Quality Engineers (SQE) Responsible for Quality Responsible for Quality Assurance of project from design phase to the Assurance of project from design phase to the commissioning. commissioning.

Project Management Engineers (Project office) Project Management Engineers (Project office) Responsible for managing project activities such as Responsible for managing project activities such as documentation, material management, resource documentation, material management, resource planning under guidance of project In charge. planning under guidance of project In charge.




Identification of Problematic Areas:Identification of Problematic Areas:Following criteria was established after consultation and Following criteria was established after consultation and

discussion with all relevant working groups:discussion with all relevant working groups:�� Replacement of Regulating Computer.Replacement of Regulating Computer.�� Safety Loops.Safety Loops.�� Measurements and Control loops that are critical / not Measurements and Control loops that are critical / not

maintainable and problematic from operational point of view.maintainable and problematic from operational point of view.Requirement Specification for I&C ModernizationRequirement Specification for I&C Modernization

The Requirement Specification were prepared after detaileThe Requirement Specification were prepared after detailed d Engineering study i.e.Engineering study i.e.�� Primary sensor and final control element would not be Primary sensor and final control element would not be

replaced.replaced.�� Modern state of the Art electronic equipment would be used Modern state of the Art electronic equipment would be used

to replace pneumatic equipment as for as possible.to replace pneumatic equipment as for as possible.


Requirement Specification for I&C Modernization (Cont.)Requirement Specification for I&C Modernization (Cont.)�� For Analog signal transmission 4For Analog signal transmission 4--20mA DC signal be 20mA DC signal be

used as a standard between field, electronic and control used as a standard between field, electronic and control room equipment.room equipment.

�� For Binary signal 24 V DC signal transmission would be For Binary signal 24 V DC signal transmission would be used.used.

�� All electronic equipment would be supplied with redundant All electronic equipment would be supplied with redundant 24VDC UPS24VDC UPS

�� Configuring PCs would be supplied by 220 VAC UPS.Configuring PCs would be supplied by 220 VAC UPS.Quality AssuranceQuality AssuranceProject QA manual was developed defining the requirement to ensure the quality & control at different phases. A QA plan was also established.



Methodology to ensure Plant Safety at diff. project phasesMethodology to ensure Plant Safety at diff. project phasesTo ensure Plant safety during installation and commissioning To ensure Plant safety during installation and commissioning

following strategies were adopted:following strategies were adopted:•• Installation of infrastructure material in accessible areas of Installation of infrastructure material in accessible areas of plant to be done during plant operation while in non plant to be done during plant operation while in non accessible areas to be done during extended shutdown accessible areas to be done during extended shutdown without interacting with any plant systems.without interacting with any plant systems.•• No change over to be made during plant operation. No change over to be made during plant operation. •• Changeover and installation of equipments would be only Changeover and installation of equipments would be only in extended shutdown and the system should be out of in extended shutdown and the system should be out of service prior to its I&C is changed.service prior to its I&C is changed.•• PrePre--commissioning team would ensure availability of commissioning team would ensure availability of individual devices and their Integrated performance using individual devices and their Integrated performance using actual process signal injection from transmitter after actual process signal injection from transmitter after changeover is complete.changeover is complete.




�� Commissioning of the new I&C system would be done Commissioning of the new I&C system would be done according to the process requirements such as shutdown, according to the process requirements such as shutdown, during the plant startup process etc.during the plant startup process etc.

�� For the commissioning of I&C systems for which plant was For the commissioning of I&C systems for which plant was required in fully operational, availability of all safety required in fully operational, availability of all safety parameters/actuations were ensured before starting of parameters/actuations were ensured before starting of commissioning of such I&C systems.commissioning of such I&C systems.

�� Operation Division would perform independent verification Operation Division would perform independent verification for all I&C loops/systems to verify that the performance of for all I&C loops/systems to verify that the performance of replaced loops are as per acceptance criteria and any replaced loops are as per acceptance criteria and any shortcomings would be brought to the knowledge of shortcomings would be brought to the knowledge of Project InProject In--charge to rectify it accordingly. charge to rectify it accordingly.

�� Safety loops would be commissioned first and their Safety loops would be commissioned first and their dynamic testing would be done before plant startup and dynamic testing would be done before plant startup and witnessed by regulatory representative.witnessed by regulatory representative.


Tools and Methods used for Effective Control Tools and Methods used for Effective Control Modernization of I&C at KANUPPModernization of I&C at KANUPP

Testing of New I&C SystemsTesting of New I&C SystemsTesting of new I&C system was carried at following stages� Performance Evaluation Tests� Factory Acceptance Tests� Site Acceptance Test� Off-Plant Testing� Pre-commissioning Tests.� Commissioning Tests.


Tools and Methods used for Effective Control Tools and Methods used for Effective Control Modernization of I&C at KANUPPModernization of I&C at KANUPP

Resource PlanningResource PlanningProject goals achieved through the utilization of resources, e.gProject goals achieved through the utilization of resources, e.g. to . to provide required equipment, tools, spares, test equipments and provide required equipment, tools, spares, test equipments and necessary installation material at right time. This tool is usednecessary installation material at right time. This tool is used to to prevent non productive effect, to assure cost effectiveness of tprevent non productive effect, to assure cost effectiveness of the he project. Resource scheduling, availability and optimization are project. Resource scheduling, availability and optimization are considered KEY to successful project management.considered KEY to successful project management.

We have done resource planning for:We have done resource planning for:�� Equipment and Spares (were procured from vendor)Equipment and Spares (were procured from vendor)�� Infrastructure material (arranged locally)Infrastructure material (arranged locally)�� Tools and Test Equipments (arranged locally or from subTools and Test Equipments (arranged locally or from sub--suppliers)suppliers)�� Test facilities were developed inside plant premises to ensure tTest facilities were developed inside plant premises to ensure timely imely testing of equipments before installation at sitetesting of equipments before installation at site

�� Manpower acquired mostly from KANUPP and was trained for projectManpower acquired mostly from KANUPP and was trained for project..


Tools and Methods used for Effective Tools and Methods used for Effective Control Modernization of I&C at KANUPPControl Modernization of I&C at KANUPP

Documentation ControlDocumentation ControlProject office was responsible for controlling multiple revisionProject office was responsible for controlling multiple revisionof the documents and retaining all previous versions for of the documents and retaining all previous versions for reference.reference.A data base A data base ““Project documentation Filing systemProject documentation Filing system”” named as named as Master Index was developed and used for proper filling and Master Index was developed and used for proper filling and numbering of various documents which were generated numbering of various documents which were generated during various phases of Project implementation.during various phases of Project implementation.

Cost ControlCost ControlCost control was managed by Project Manager and Project Cost control was managed by Project Manager and Project InIn--charge. During their special meetings any cost over run charge. During their special meetings any cost over run was discussed in the presence of Project Team and was discussed in the presence of Project Team and strategies were formulated to control the cost with in the strategies were formulated to control the cost with in the budget provision.budget provision.


Tools and Methods used for Effective Control Tools and Methods used for Effective Control Modernization of I&CModernization of I&C

Implementation PlanImplementation PlanImplementation plan Implementation plan is very important. The realistic scheduling, is very important. The realistic scheduling, ensure proper implementation of the project, we made this plan ensure proper implementation of the project, we made this plan with incremental change philosophy.with incremental change philosophy.It was divided into following phases:It was divided into following phases:

�� Infra Structure PhaseInfra Structure Phase�� Evaluation PhaseEvaluation Phase�� Implementation Phases (First Phase, Second Phase, Third Implementation Phases (First Phase, Second Phase, Third Phase) Phase)

Schedule ControlSchedule ControlSchedule control has been used to plan the work and for Schedule control has been used to plan the work and for evaluation of progress. The schedule consists of removal of old evaluation of progress. The schedule consists of removal of old Equipments, Installation of equipments area wise and other Equipments, Installation of equipments area wise and other activities related to practivities related to pr--commissioning and commissioning. All commissioning and commissioning. All efforts were made to keep the schedule updated and remained efforts were made to keep the schedule updated and remained effective throughout the Project.effective throughout the Project.


Tools and Methods used for Effective Tools and Methods used for Effective Control Modernization of I&CControl Modernization of I&C

Progress EvaluationProgress EvaluationIt has been done with different manners, i.e. It has been done with different manners, i.e. All SDE,SIE,SQE are responsible for preparation of their All SDE,SIE,SQE are responsible for preparation of their respective areas weekly progress report.respective areas weekly progress report.

Preparation of Weekly and Monthly report:Preparation of Weekly and Monthly report: Responsibility of Responsibility of PE, reported to PI and PMPE, reported to PI and PM

Monthly Progress Evaluation Meeting:Monthly Progress Evaluation Meeting: Called by PI and Called by PI and attended by all attended by all

SDEsSDEs, SIE and SQE and Minutes of the meeting recorded by , SIE and SQE and Minutes of the meeting recorded by PE.PE.

Follow up action:Follow up action: Taken by respective SDE,SIE,SQE and SCE Taken by respective SDE,SIE,SQE and SCE and copies of report forward to PM(TUP)and copies of report forward to PM(TUP)

Quarterly Progress report:Quarterly Progress report: PI reported to PM and top PI reported to PM and top management of PAEC.management of PAEC.


Development of Support Facilities to Development of Support Facilities to support I&C Modernizationsupport I&C Modernization

Support FacilitiesSupport FacilitiesWith the project in mind it was felt that support facilities for the C&I modernization project was very essential. The facilities that were envisaged were: � Offline Test and Calibration facility (Static Calibration)� Dynamic Test Facility (I&C Test Rigs)

The Dynamic Test facility was also used for training of personnel for the new technology and man-machine interface.


TEST RIGSSupport FacilitiesSupport Facilities

Process C&I Devices (New or repaired) can be tested on these Rigs for observing their performance in dynamic conditions before installation on plants/ processes. Equipment i.e. heat exchanger, pump, relief valve, etc. can also be tested.


Lesson Learned and ExperiencesLesson Learned and Experiences�� Importance of human resourceImportance of human resource� Had we not the competent manpower we could not have implemented such a huge retrofitting project on our own saving a lot of foreign exchange. �� Testing / TrainingTesting / TrainingEstablishment of Pressure, Temperature, Level & Flow Test Rigs proved its worth by providing:� Dynamic testing of new C&I devices.� Support of new Control and Instrumentation system. � Operators training on new panel equipment

�� Procurement ProblemsProcurement Problems� At the time of procurement the size of panel instruments were larger but later supplies were of different sizes. Hence it is advisable to procure ample spares. �� Panel ModificationPanel Modification� In our case steel panels modification was quite difficult hence it is better to have mosaic panels.


Overview of ChangeOverview of Change

OLD PANEL WITH OLD PANEL WITH PNEUMATIC PNEUMATIC CONTROLLERSCONTROLLERS

NEW PANEL WITHNEW PANEL WITHPLC CONTROLLERSPLC CONTROLLERS

KANUPPKANUPPCONTROLCONTROL

ROOMROOM

PANEL PANEL ENGINEERINGENGINEERING

GIVE AN EASEGIVE AN EASETO TO

OPERATORSOPERATORS

Oct, 2007Oct, 2007 IAEAIAEA--CNCN--155/073155/073 3131NEW REACTOR POWER REGULATION CONSOLE & PROCESS INFORMATION SYSTENEW REACTOR POWER REGULATION CONSOLE & PROCESS INFORMATION SYSTEMM

OLDOLDCONSOLECONSOLEWITHOUTWITHOUTVDUVDU


Oct, 2007Oct, 2007 IAEAIAEA--CNCN--155/073155/073 3232MANMAN--MACHINE INTERFACE OF NEW I&C SYSTEMSMACHINE INTERFACE OF NEW I&C SYSTEMS

OLD LINEOLD LINEPRINTERSPRINTERS



ConclusionConclusionEffective Control of I&C modernization was achieved using appropriate methods and tools that provided the support to implement the project successfully and meeting the desired objectives. As I&C modernization was of a big nature including all safety loops, most of the control loops and significant numbers of measurement loops therefore, the project was a complex one and if the proper managing tools were not used in spite the availability of all the resources the project could not have been successfully accomplished. Thus proper project management is necessary to execute a project of this nature and complexity and if appropriate tools are used the success is achievable.


Karachi Nuclear Power Plant, PakistanKarachi Nuclear Power Plant, Pakistan

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Effective Control of Instrumentation and Control (I&C ...Project Management Engineers (Project office) Responsible for managing project activities such as documentation, material management,