Use of modern technologies in the Paks NPP

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Use of modern technologies in the Paks NPP

• TÚRI Tamás
• Project manager

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Hungary
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Satellite picture of Paks and the NPP
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Aerial photograph of the NPP
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General view of the Paks NPP
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Hungarian Eletricity Production
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Total Electricity Production of the Paks NPP
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Cumulative Load Factor
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Content

• Life time extension and IC
• What to do?
• What have we done?
• Lessons learnt

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Life time extension and IC

• Tasks for the life time extension
• To prove that the non changeable components of
  the plant can serve during the extended life time
• To demonstrate that the performance of the
  changeable components are maintainable during the
  extended life time and to provide the way of this
  maintenance

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Life time extension and IC contd

• IC is changeable and life time of IC systems is
  much shorter than the extended life time of the
  plant, therefore refurbishment is needed.
• The architecture and even the functions of the
  20-30 years old IC were determined by the
  technologies available at that time.
• Today technology gives us the chance to design
  systems with soft technologies, offering higher
  level of safety and availability with less volume
  of equipment and with less cost of maintenance.
• How much of the offered convenience of the new
  technologies can be accepted? (Albert Einstein
  Technological progress is like an ax in the hands
  of a pathological criminal).

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Tasks of refurbishment preparation
What to do?

• To justify that the refurbishment is
• feasible,
• economical,
• Necessary for life time extension
• Establish a methodology
• Formal description of the functionality of the
  Process Control System in a database
• Definition of the ideal architecture
• Identification of the optimal scope of subsystems
  to be refurbished in a single step
• factor of physical conditions
• factor of importance
• factor of refurbishment (product of the previous
  two)
• Specification of equipment and tools to be used
  (or to be not used)
• Literature research

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Description of the Process Control System
Operational Procedures

• Funkcionális specifikáció

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What to do?

• Development environment
• The application SW should be exclusively in the
  form of function blocks
• The user wants to handle (independence from the
  supplier)
• The designer (process engineer) can create the SW
• ProfiSim development environment with simulation
• Editor dealing with the function blocks
• Simulation tests
• Multilevel structure
• Representation of the operating HW
• Automated, repeatable tests
• Multiprocessor, large system
• Handling the communications
• Handling failures
• Living documentation
• Open SQL database structure, output for other
  systems

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What have we done? RPS refurbishment

• Contract with Siemens AG 1996
• Unit 1 commissioning 1999
• Unit 2 commissioning 2000
• Unit 3 commissioning 2001
• Unit 4 commissioning with new, Unit independent
  SW 2002
• Unit 1,2, and 3 new, Unit independent SW 2003

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Safety IC reconstruction lifecycle (IEC 880)
The demands of users, corporate, national and
international regulations, outputs from the
establishing phase, proposals
Establishment
System requirements
Preparation
System specification
Conventional IC requirements
Computer hardware requirements
Software requirements
Software design
Computer hardware design
Conventional IC design
Software coding
Computer hardware manufacturing
Conventional IC manufacturing
System analysis
Computer system integration
Design and manufacturing
Factory acceptance testing
On-site installation and integration
System, I/O testing site acceptance test
Installation
Trial operation
Operation
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Architecture of the new RPS
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Representative Configuration

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Factory Acceptance Testing
MMI of the RPS
Representatives of the Supplier and the Customer
TEST COMPUTER
I/O INTER-FACE
RPS FULL CONFIGURATION
TEST CASES
AI
DI
TEST ORACLE
MMI
AO
DO
COMPA-RATOR
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RPS hardware or RPS model in the loop tests
FULL SCOPE SIMULATOR
PROCESS MODEL IC MODEL
RPS MODEL
MMI
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Reactor Pressure controller
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Reactor pressure with the original controller
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Reactor pressure with the new controller
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Lessons learnt

• The scope for a single step refurbishment was not
  optimal
• The actuator controllers were not refurbished,
  therefore interface design was needed
• The HMI was not refurbished, therefore interface
  design was needed
• The scope of the upgrade was too small, but the
  administration and licensing was quite big,
  therefore the efficiency of engineering was not
  optimal
• The specification was limited by the Russian
  design because of routine. More modifications
  should have been specified for the operational
  transients.
• The SW coding was conventional due to lack of
  time. The automatic code generation should be
  solved in the future.

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Thank you for your attention!

• Any questions?

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(No Transcript)
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The reactor hall
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The turbine hall
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Old safety instrumentation and logic panels
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Old safety instrumentation and logic panels 2
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The neutron flux pre-amplifiers
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Start-up and periodic testing
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Safety cable tray installation
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Safety cable trays in the turbine hall
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Space preparation for the new cabinets
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Installed new safety IC cabinets
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The safety IC representative configuration
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The TS computer
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The consoles in the old and the new systems
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The panels in the old and the new systems
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Main control room installation
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Final arrangement in the main control room
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Back view of the new RPS panels in the MCR