Replacing Analog Meters with Digital Solutions

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Replacing Analog Meters with Digital Solutions
Gerry Waterhouse Site Manager, NLI Canada
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Existing Scenario

• The nuclear industry is faced with the challenge
  of maintaining (and improving) the reliability of
  old analog instrumentation and controls.
• This challenge is compounded
• Dwindling OEM support
• Shrinking internal plant expertise
• Equipment obsolescence
• Inherent difficulties of safety related digital
  equipment

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Case Study

• Replacement of bargraph meters at FPL St. Lucie.
• Qty. 700 Versatile Model 2000 bargraph meters
  were replaced
• Increasing failures
• Parts obsolescence
• Expensive refurbishments
• Existing fluorescent vacuum display has a life
  expectancy of 5 - 8 years on average.

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Case Study (cont.)

• A replacement solution was selected using a
  digital bargraph meter manufactured by OTEK.
• The replacement meter was designed to be a
  one-for-one replacement with the existing
  meter
• Open frame design to Work with existing Versatile
  housings
• Maintain existing wiring and terminations
• No new cuts in the control room panels

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Case Study (cont.)

• One for one replacement design also reduced the
  need to revise plant drawings, technical
  specifications and training manuals.
• Significantly reducing the cost of the design
  change.
• Great effort was put into the design and
  production of the meter displays to meet the
  strict requirements of the plant operators.

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Case Study (cont.)

• Qty. 700 bargraph meters were supplied,
  consisting of single, dual, vertical and
  horizontal styles.
• Custom scale plates exceeded 150.

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Digital Meter Benefits

• Improved HMI
• - Automatic tri-color bargraph
• - Bright LED display
• - Excellent visibility under virtually all
  light conditions, greater distance
• Improved MMI
• Multiple options for Serial Communication
• State-of-the-art technology
• Dual micro-processor faster response time

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Benefits (cont.)

• A2D failure indication
• Alarm set points
• Main processor failure detection
• Higher accuracy (4 digits vs. 3)
• Greater Reliability
• Life Time Warranty
• Upgrade possibility to DCS/SCADA interface

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Safety Related Meters

• Safety related meters are supplied with
  qualification in accordance with
• IEEE Std. 344 (Seismic)
• IEEE Std. 323 (Mild Environment)
• EPRI TR-102323 (EMI/RFI)
• IEEE Std. 7-4.3.2 (Software VV)
• 100 of the meters are dedicated in accordance
  with Methods 1 and 2 of EPRI NP-5652.
• Supplied as safety related per NLIs 10CFR50
  Appendix B, 10CFR21 and Z299.2 Quality Assurance
  Program.

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Documentation

• The following documentation is provided with the
  meters
• Certificate of Compliance
• Qualification Report
• Verification Report
• Instruction Manual
• Drawing Package

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Conclusion

• Reduced dependency on obsolete equipment.
• Improved performance, accuracy and reliability.
• Prequalified product for Class 1E applications.
• Custom design for plant application eliminating
  need for rewiring and cutting new holes in the
  control room panels.
• Reduced design change package
• Minimal drawings and tech specs effected