IAEA TWGNPPCI MEETING

1
National Report on Nuclear Power Plant ICin the
Republic of Korea

• IAEA TWG-NPPCI MEETING
• May. 23 - 25, 2005, Vienna
• by Hang Bae Kim
• KOREA POWER ENGINEERING COMPANY, INC.

KOPEC
2
ltlt Contents gtgt

• NPP Overview
• IC Overview
• New Construction
• RD Programs
• IC Upgrade
• Conclusion
• Suggestions

3
NPP Overview(1)

• Nuclear Power Plants

Ulchin Nuclear Power Site 1, 2, 3, 4, 5, 6
NPP in Operation
Shin-Ulchin 1, 2
NPP under Construction
NPP in Planning
Wolsong Nuclear Power Site 1, 2, 3, 4
Shin-Wolsong 1, 2
Yonggwang Nuclear Power Site 1, 2, 3, 4, 5, 6
Kori Nuclear Power Site 1, 2, 3, 4
Shin-Kori 3, 4
Shin-Kori 1, 2
4
NPP Overview(2)

• Nuclear Energy Program in Korea

Next Generation

APR1400
24 9 3
3rd Generation (Technology Upgrade
OPR1000)
(Standardization OPR1000) (Technology
Self-Reliance)
Shin Wolsong 12
Shin Kori 12
KEDO 12
Ulchin 56

Yonggwang 56
Ulchin 34
Wolsong 2-4
AECL
Yonggwang 34
2nd Generation (non-Turnkey)


Ulchin 12
Framatome
Yonggwang 12
Kori 34
20 Units in operation 4 Units under
construction 4 Units planned
(Turnkey)

Wolsong 1
AECL
1st Gen.
Kori 2
Kori 1
1970 1980 1990
2000 2015
5
NPP Overview(3)
6
NPP Overview(4)

• Projection of Electricity Generation

7
IC Overview (1)

• IC Programs (2003-2005)
• New Construction
• APR1400 MMIS (Shin-Kori 34)
• Core Protection System for OPR1000
• Research and Development
• KNICS (Korea Nuclear IC System)
• Automatic Spec. and Code Generation
• Ultrasonic Flow Meter
• Upgrade
• IC Upgrade Strategic Plan

8
IC Overview(2)

• 1st Generation use of relay technology
• Implemented by various relays
• Kori unit 1 Reactor Protection Systems (RPS),
  etc.
• 1st upgraded with digital modules in Korea(1998)
• 2nd Generation use of solid-state technology
• Implemented by analog Integrated Circuit (IC)
  chips
• Kori 2,34, Yonggwang 12, Ulchin 12 RPS,
  ESFAS, etc.
• 3rd Generation use of hybrid technologies
• Implemented by microprocessor-based and relay
  components
• Wolsong 1,2,34, Yonggwang 3,4,56, Ulchin 34
  RPS, ESFAS, PCS, etc.

9
IC Overview(3)

• 4th Generation use of PLC-based computer
  technologies
• Implemented by digital PLC-based computers and
  software systems
• Ulchin 56, Shin Kori 12, Shin Wolsong 12
  DPPS, DESFAS-AC, data communications, etc.
• 5th Generation use of advanced HMI technologies
• Implemented by digital computers and software
  systems
• Integrating advanced human-system interfaces into
  main control room and remote shutdown stations
• Shin Kori units 34(APR-1400) DPPS, ESF-CCS,
  MCR, Soft Controls, Graphic Display Systems, etc.

10
IC Overview(4)

• IC Systems Digitalized in Korean Nuclear Power
  Plants

Systems
Reactor Trip
ESFAS
Protection
NSSS
Turbine Control
Main Control
PCS
Plants
System
Systems
Process
Control
Board
Relay Logic
Relay Logic
Foxboro
Foxboro
Foxboro
Kori No. 1
DCS
Conventional
(W/H)
(W/H)
H-line
H-line
H-line
Spec200
Spec200
Spec200
Kori No. 1
Relay Logic
Relay Logic
Spec200m
Spec200m
Spec200m
DCS
(Upgraded
Conventional
(W/H)
(W/H)
(Foxboro)
(Foxboro)
(Foxboro)
in 1998)
SSPS
SSPS
Kori No. 2,3,4
7300
7300
7300
Mark V
Relay Logic
Relay Logic
Conventional
Analog
Analog
Analog
(GE)
YGN No. 1,2
(W/H)
(W/H)
Spec200
Relay Logic
Relay Logic
Analog
ILS
Mark V
Spec200m
YGN No. 3,4
Conventional
(ABB-CE)
(ABB-C
E)
(ABB-CE)
(Forney)
(GE)
(Foxboro)
Spec200
Relay Logic
Relay Logic
Analog
PCS
Mark V
Spec200m
Hybrid
Ulchin No. 3,4
(ABB-CE)
(ABB-CE)
(ABB-CE)
(Eaton)
(GE)
(Foxboro)
DCC X/Y
Mark V
Relay Logic
Relay Logic
Analog/PDC
Analog/Relay
Computers
Wolsong No. 1,2,3,4
Hybrid
(GE)
(AECL)
(AECL)
(AECL)
(AECL)
Control
PLC
Relay Logic
Relay Logic
Analog
PCS
Mark V
Hybrid
YGN No. 5,6
(OMRON)
(Eaton)
(GE)
(ABB-CE)
(ABB-CE)
(ABB-CE)
PLC
PLC
PLC
Analog
PCS
Mark V
Ulchin No. 5,6
Hybrid
(W/H)
(W/H)
(OMRON)
(HFC)
(GE)
(W/H)
Teleperm XP
Shin Kori No. 1,2
PLC
PLC
Analog
Mark VI
PLC (OMRON)
Hybrid
Shin Wolsong No.1,2
(GE)
(W/H)
(W/H)
Ovation (W/H)
(Siemens)
(W/H)
Shin Kori No. 3,4
PLC
PLC
Analog/PLC
Ovation
PLC
Mark VI
Compact
(APR-1400)
(W/H)
(GE)
Workstation
(W/H)
(W/H)
(W/H)
(W/H)
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New Construction (APR1400 MMIS) (1)
APR1400 Overview

• Major Spec.
• Capacity 1450 Mwe (4000 MWth)
• Plant life time 60 years (CDFlt10-5/RY)
• Construction period 64 months (48 for Nth
  plant)
• Operator response time longer than 30 min.
• Deployment Schedule
• Shin-Kori 34 and 2 more units by 2015

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New Construction (APR1400 MMIS) (2)
Major Design Features

• Computer-based Advanced MCR
• Compact workstation
• Large Display Panel
• Safety Console
• Soft Control
• Fully Digitalized NSSS and BOP IC Systems
• PLC for safety and DCS for non-safety IC Systems
• Human Factors Engineering Verification
  Validation
• Computerized Operating Procedures

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New Construction (APR1400 MMIS) (3)
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New Construction (APR1400 MMIS) (4)

• Block Diagram for APR1400 IC Systems

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New Construction (APR1400 MMIS) (5)

• Dynamic Mock up

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New Construction (APR1400 MMIS) (6)

• Soft Control Template

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New Construction (OPR1000 CPC) (1)

• Core Protection Calculator (CPC) Overview
• Safety system for DNBR, LPD trip
• Four independent channels
• CEA signals shared between CPC and CEAC using
  fiber optic isolation devices
• Problems
• Obsolete hardware
• Difficult maintenance of software
• Implemented with assembly language
• Single point of failures
• Two channels of CEAC (actuated by ½ logic)
• Failure of signal Isolators (CEA input signals to
  CEAC)

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New Construction (OPR1000 CPC) (2)

• Hardware and Configuration
• PLC for safety function
• Color flat panel display for operators module
• Network for intra-channel communication
• Serial data communication for inter-channel data
  sharing
• Software
• Function block structure
• Customized function blocks for PLC using C
  language
• Independent verification and validation of
  software
• Preliminary software hazard analysis
• Requirement traceability matrix
• Code review
• Module, unit, system integration testing

19
New Construction (OPR1000 CPC) (3)

• SYSTEM BLOCK DIAGRAM

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RD (KNICS) (1)

• Objective (Korea Nuclear IC System)
• Localization of major IC systems and equipment
  to meet the APR1400 design requirements
• Project Period
• Phase I July 2001 June 2004, Prototype
• Phase II July 2004 June 2008, Final Product
  Licensing
• Project Participants
• KOPEC, DHIC, POSCON, WOORI Tech., Sam-chang, BNF
• KAERI, KERI, KEPRI
• SNU, KAIST, Korea Univ. and etc.
• KINS

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RD (KNICS) (2)

• Major Activities
• Development of digital systems and equipment
• Localization and licensing of safety-grade PLC
  and digital RPS and ESFCCS
• Safety-grade software qualification
• Development of Control Rod Control System
• Localization for existing next-generation NPPs
• Development of Distributed Control System
• Localization of hardware platform for monitoring
  and control systems for NPPs

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RD (KNICS) (3)
KNICS Architecture
Safety Console
LDP Controller
RWC
RSP
EOF
TSC
VDU/Soft Controller
VDU/Soft Controllers
LDP Controller
RO TO Console CRS/SS/STA Console
QIAS-P
Operation Device Network
Control Network
EWS Other I/O
QIAS Network
DBMS
Alarm Server
IPS
CPS
Unit Level
Information Network-Fast Ethernet 100Mbps
System Level
Control Network-Ethernet Token 100Mbps
Safety Network Inter-ch. Profibus 12Mbps
Digital Signal Acquisition Cabinet
Reactor Protection Cabinet Ch-A
BOP Sys Component Control Cabinet AUX.
SYS. HVAC CCS Field Network E-T 10Mbps
Electrical System Control Cabinet Field
Network E-T 10Mbps
BOP Control System Cabinet T/G
Protection Field Network E-T 10Mbps
NSSS Component Control Cabinet PPCS PLCS CVCS Fi
eld Network E-T 10Mbps
Power Control System Cabinet RRS CEDMCS
RPCS Field Network E-T 10Mbps
NSSS Control System Cabinet FWCS SBCS APS Field
Network E-T 10Mbps
Gas Stripper
Safety Network Inter-ch. Profibus 12Mbps
NSSS Integrity Monitoring Cabinet
Safety Network Inter-ch. Profibus 12Mbps
Boronometer
ICCMS
PRM
Digital signal Acquisition
CPC Ch-A
RCPSSSS
ESF-CCS Cabinet Ch-A
Field Network Profibus 6Mbps
A/D Conversion
Digital Signal Acquisition
Field Network Profibus 6Mbps
Digital Signal Acquisition Cabinet
A/D Conversion
Local Bus
To Control Systems
Local Level
Automatic Power Electronics Cabinet
Generator Transformer Protection Cabinet
Process Conditioning Cabinet
Process Conditioning Cabinet
ENFMS Cabinet_A
Reactor Trip Switchgear
Electrical System Logic Cabinet
Process Conditioning Cabinet
Process Conditioning Cabinet
ENFMS Cabinet_A
Process Conditioning Cabinet
Process Conditioning Cabinet
ENFMS Cabinet_A
ENFMS Cabinet _A
Plant Field
KNICS Scope
Multiplex Data Link
Multiplex Data Highway
Hard Wired
(Point-to-point)
(Multi-drop)
23
RD (Software Tool) (1)

• Main Purpose
• Develop the methodology to generate the automated
  software design specification and source code for
  the nuclear IC systems.
• Software Engineering Tools Integrated into the
  System
• Requirements management and traceability analysis
  tool
• Modeling and auto-code generation tool
• Object oriented compiler such as C and JAVA
• Code auto testing tool
• Configuration management tool

24
RD (Software Tool) (2)

• Overall Scheme

25
RD (Software Tool) (3)

• Prototype

26
RD (UFM) (1)

• Background
• Utility concerned the power derating since 1998
• Derating 20 40 MWe
• Fouling was presumed as main cause
• Needs for alternative method to measure the
  feedwater flow
• Main Purpose
• Develop the technology for adopting UFM in
  feedwater flow measurement in Korea NPPs
• Measurement accuracy lt 0.6
• Prepare topical report
• Support licensing

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RD (UFM) (2)

• Activities
• Develop the technology for application of UFM in
  feedwater measurement
• Select UFM vendor
• Perform performance and reliability tests
• Measure feedwater flow in operating plants and
  verify applicability of UFM
• Verifying actual measurement uncertainty
• Perform analyses
• Effects of application of flow correction factor
• Calculations of uncertainty of reactor power
• Prepare topical report for UFM application

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RD (UFM) (3)

• Flow Measurement Using UFM

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IC Upgrade (Plan) (1)

• Objective

• Development of methodology of reliability
  evaluation and
• evaluation system for IC upgrade
• Planning optimal upgrade strategy through the
  reliability evaluation of major IC systems
• Development of IC upgrade architecture and
  technical criteria
• Large-scale upgrade implementation method for one
  outage

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IC Upgrade (Plan) (2)

• Overall Flow

Evaluation of current state of IC System
IC System Reliability Assessment
Weight Allocation among factors
Evaluation Factor
Failure Mode Effect Analysis (FMEA)
Extraction of the Degree of System
Reliability
Prioritization Of Upgrade Candidates
Cost-Effectiveness Analysis
Question-sheet
- Staff-Interview - Operation Data - Design
Data
Constraints and Limitation
Considerations

• Tech. Criteria
• Architecture

Final Upgrade Planning
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IC Upgrade (Plan) (3)

• Process

• Determination of Evaluation Factors

• Development of Evaluation Model

Establishing Evaluation System

• Enhancement
• of Performance
• Reduction of
• O/M Cost
• Increase of Reliability Safety

• Weighting Allocation among Factors
• and Questions

• Interviewing with Plants Staffs

• Performing FMEA

Planning optimal Upgrade Strategy

• Establishing DB

• Development of IC Architecture

• Development of Technical Criteria

Enhancement
Evaluation
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Conclusion

• Korea Has Achieved a Progressive Nuclear Program
• Turnkey Plant --gt OPR(KSNP) --gt OPR --gt
  APR1400
• IC System Contribution
• Functional improvements and digitalization for
  new construction
• Replacements and upgrade for operating plants
• Advanced MMIS for next generation plants
• RD for equipment and system localization

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Suggestions

• Pressing Needs
• Practical IC Upgrade Strategy and Methodology
• Preventive Maintenance Technology
• Issues for Future Meeting
• MMIS(HFE) Design Process
• Cyber Security
• Better Interaction
• IC Experts Consulting Pool (specialty,
  experience)