M d i ti f C&I fM d i ti f C&I fModernization of C&I for Modernization of C&I for Nuclear Power PlantsNuclear Power PlantsNuclear Power PlantsNuclear Power Plants

A. K. Chandra

Exec Dir (C&I, E, R&D-ES)Nuclear Power Corporation of India Ltd.

DAE-BRNS Seminar on “Applications of Computer & Embedded Technology” VECC, October 28-29, 2009Embedded Technology VECC, October 28 29, 2009

CONTENTS

Evolution of Control Rooms in NPP

Impact of usage of computers

Experience with use of computers

Design of C&I for 700 Design of C&I for 700 MWeMWe plantsplants

Present NPP Scenario in IndiaPresent NPP Scenario in IndiaPresent NPP Scenario in IndiaPresent NPP Scenario in India

PHWR Program– 17 operating NPPs (capacity 4020 MWe)– 17 operating NPPs (capacity 4020 MWe)

– 3 plants under construction (capacity 660 MWe)

4 l t (2800 MW it ) d l h– 4 plants (2800 MWe capacity) under launch

– 6 plants (4200 MWe capacity) to follow

LWR Program– 2 plants under construction (capacity 2000 MWe)

3

p ( p y )

– 28 more to follow (capacity 42000 MWe approx.)

Control Room in NPP 1/2Control Room in NPP 1/2

The Control Room is designed to provide the i hoperator with

− complete information on the status of the plant i t d li bl tequipment and applicable systems,

− capability to control plant during all operational states and accident conditionsstates and accident conditions.

− support information sharing between crew and improve teamworkimprove teamwork

− ease of operation and monitoring

Control RoomControl Room in NPP 2/2

Panels provided in the Control Room, consist of several components to monitor and control the status of various plant systems and are designed for standing operation.

Grouping of information and controls on panels is p g pdone by process, for convenience of operator.

Physical design is based on anthropometrics &Physical design is based on anthropometrics & ergonomic considerations.

MAPS Unit – 2 Control Room

6

Introduction of CBS in NPPs 1/2Introduction of CBS in NPPs 1/2Introduction of CBS in NPPs 1/2Introduction of CBS in NPPs 1/2

Replacement of panel components /Functionality common to several processes

Channel Temperature Monitoring System (MAPS 1985))Digital Recording System (NAPS 1990)Control Room Computer System (NAPS 1990) Programmable Digital Comparator System (KAPS 1993) Programmable Logic Comparator (KGS-2 1999)Programmable Logic Comparator (KGS-2 1999)

Introduction of CBS in NPPs 2/2Introduction of CBS in NPPs 2/2

Process Specific Functions

Reactor Regulating System (NAPS 1990)Fuel Handling Control System (NAPS 1990)g y ( )Process Control System (KGS-2 1999)Electrical SCADA (KGS-2 1999)

Impact of CBS on ControlImpact of CBS on ControlImpact of CBS on Control Impact of CBS on Control Rooms 1/3 Rooms 1/3

Superior Operator Interface with introduction of soft screen displays (and often, controls) with attendant flexibilityP id hi h l ti ( d d) d tProvide high-resolution (recorded) data Provide a printer logImproved diagnostics supportImproved diagnostics support

Impact of CBS on ControlImpact of CBS on ControlImpact of CBS on Control Impact of CBS on Control Rooms 2/3Rooms 2/3

As newer functions identified for computerization, t di l t ti dd d t diloperator display stations were added steadily.

These provided detailed plant information and parameter setting facilitiesparameter setting facilities.Increasing numbers of these stations necessitated introduction of Operator Information Consoles in pfront of the panels.OICs were designed for seated operations.

KGS KGS –– 2 Control Room2 Control Room

KGS KGS –– 2 Control Room2 Control Room

Impact of CBS on ControlImpact of CBS on ControlImpact of CBS on Control Impact of CBS on Control Rooms 3/3Rooms 3/3

Some reduction of corresponding panel instrumentation e.g. reduced number of window annunciations (35%) , recorders (30%), indicating meters (72%) etcmeters (72%) etc.

Single loop controllers hand-switches andSingle loop controllers, hand switches and pushbuttons also reduced.

Use of CBS in TAPP-3 4 KG-3 4Use of CBS in TAPP 3,4, KG 3,4 RAPP-5,6

All major Control, Monitoring, Test & Surveillance and Operator Information functions are CBSare CBS.Some protection functions use microprocessorsInformation from these systems and from standInformation from these systems and from stand alone controllers & recorders sent to a Computerized Operator Information System (COIS) through GatewaysInformation from COIS sent over VSAT to HQ

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Experience with CBS inExperience with CBS inExperience with CBS in Experience with CBS in Control Rooms 1/3Control Rooms 1/3

System specifications focus on the functionality d h i l fand the essential MMI features

E h t i ( ft ) d l d b diff tEach system is (often) developed by different teams

Each system (often) offers unique MMI reflecting the design history / legacy of the design teamg y g y g

Experience with CBS inExperience with CBS inExperience with CBS in Experience with CBS in Control Rooms 2/3Control Rooms 2/3

System Design for a particular system often presumes continuous operator attention on the computer system screencomputer system screenTendency to introduce excessive interactive functionsfunctionsTendency to provide large amount of system diagnostic informationTendency to load features with marginal utility eventually making these systems very complex

Experience with CBS inExperience with CBS inExperience with CBS in Experience with CBS in Control Rooms 3/3Control Rooms 3/3

Continuous operator attention is not possible in practice, because necessary to view large number of MCRPs as well as soft screens

Lack of total familiarity with system interactive features can lead to underutilization of system capabilities

Design Considerations for Design Considerations for futurefuture 1/41/4

Control Rooms need to be made compact with view to:

– Ease Operation and Monitoring

– Improve Communication between operators

– Provide seated operation (effective in enhancing team work)

Information has to be structured at plant, system and component level

Introduce Operator Support functions, particularly prioritized Alarm Reporting

Design Considerations forDesign Considerations forDesign Considerations for Design Considerations for future 2/4future 2/4

Re-examine system boundaries and merge functions wherever applicable– Leads to reduction in number of systems and number of

corresponding display screens

Flatten system architectures

Introduce Operator Support functions

Design Considerations forDesign Considerations forDesign Considerations for Design Considerations for futurefuture 3/43/4

Use of DCS is virtually integral to design of C C l RCompact Control Room– Replaces autonomously operating functionally

distributed systems reduction of displaydistributed systems, reduction of display screens

– Uniformity of MMIUniformity of MMI– Complete overview of plant processes– Reduction in cabling, networking, terminationsg, g,

Design Considerations forDesign Considerations forDesign Considerations for Design Considerations for futurefuture 4/44/4

Large Display Panel allows faster operator f i iassessment of situation

– Can be seen from distanceR d i ti– Reduce communication gaps

– Allow simultaneous viewing and sharing of information rather than reportinginformation rather than reporting

– Allow team discussions during event rather than post eventp

Design of C&I for 700 Design of C&I for 700 MWeMWePlants (MCR)Plants (MCR) 1/51/5

Each panel component examined to consider requirement to be retained as “physical”requirement to be retained as physical

All components pertaining to Ia systemAll components pertaining to Ia system functionality retained

All components pertaining to Ib, Ic, NINS category, barring few, removed and made “soft”

Reduction In Components D T S ft HMIDue To Soft HMI

Component Total Quantity

Changed to soft

Changed to soft control with

Hardwired controlQuantity to soft

controlcontrol with

hardwired back-up

control

Controls 1472 805 192 475(Hand

Switches andPush Button)

(55%) (13%) (32%)

Controllers 78 45(58%)

15(19%)

18(23%)

Indicating t

418 257(61%)

36(9%)

125(30%)meters (61%) (9%) (30%)

Recorders 16 15(94%)

--- 1(6%)

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Design of C&I for 700 Design of C&I for 700 MWeMWeplants (MCR)plants (MCR) 3/53/5

10 Control Room panels

– Three for reactor systems

– One equipment / personnel protection

– Three for electrical systems

– Three for FHC

5 Large Video Screens 9 Operator Information Consolesp

Proposed SchemeProposed Scheme--2 for MCRP arrangement2 for MCRP arrangement

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25SCHEME-2 (3-D VIEW)

Design of C&I for 700 Design of C&I for 700 MWeMWePlants (DCS)Plants (DCS) 1/31/3

Absorbed all “converted” soft components

Re-examined system boundaries and “clustered” f ti h li blfunctions wherever applicable

Correlated comp ter s stem bo ndaries to processCorrelated computer system boundaries to process boundaries breaking the tradition of computerizing “functions”

Th t t l f I/O id d i 42586 i l d thThe total no. of I/Os provided i.e. 42586 nos. includes the following:

1 ESCADA 3600 I/O1. ESCADA 3600 I/Os

2. TG 13500 I/Os

3. Fuel Handling System 1500 I/Os

4 Standalone Systems 6500 I/Os4. Standalone Systems 6500 I/Os

Total of 1 to 4 above 25000 I/Os

Thus, the estimated no. of Inputs and Outputs related to the restructured Computer Based System is: 42000 – 25000 = 17000

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17000.

Design of C&I for 700 Design of C&I for 700 MWeMWePlants (DCS)Plants (DCS) 2/32/3

Devised integrated architectures of such clusters keeping in view

f l ifi isafety classificationchannel segregation

L d t d fi iti f i t l i DCS dLead to definition of virtual, generic DCS and reduction in number of display screens Reduction in computer systemsReduction in computer systems

– Nearly 15 systems merged into four– Corresponding reduction in display screens

Safety Test & Monitoring Systems(STMS Group A) Architecture(STMS Group-A) Architecture

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Optimization of Engineering of C&I

• Interconnections from one row of CBS toanother row of CBS wiring through directcabling.

• Main Control Panels to CBS connectivityMain Control Panels to CBS connectivitythrough direct cabling.

The above wiring scheme reduced CDF byb t 48% d BTC ti b 30%

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about 48% and BTC connections by 30%.

C&I for 700C&I for 700 MWeMWe plantsplants ––C&I for 700 C&I for 700 MWeMWe plants plants Summary 1/2Summary 1/2

Compact Control Room (seated operation)

Improved process – system correlationImproved process system correlation

Reduced complexity of engineering drawingsdrawings

Reduced wiring lengths and i iinterconnections

Reduced construction time

C&I for 700C&I for 700 MWeMWe plantsplants ––C&I for 700 C&I for 700 MWeMWe plants plants Summary 2/2Summary 2/2

Reduced number of systems – implemented as DCS

Standardized hardware

Standardized MMI and associated softwareStandardized MMI and associated software

Standardized embedded software

THANK YOU