Transcript I&C Status at EDF & Recommendations to IAEA IAEA TWG-NPPIC Meeting 20-22 May 2009 Vienna Patrick Salaün – EDF.

I&C Status at EDF
&
Recommendations
to IAEA
IAEA TWG-NPPIC Meeting
20-22 May 2009
Vienna
Patrick Salaün – EDF
EDF
Nuclear Power Plants
Studies concerning the I&C
Systems
Nuclear Power Plants at EDF, in France

PWR 900 MW series : 34 units
6 CP0, 18 CP1, 10 CP2 units
Connection to the grid: 1977 - 1988
3rd ten-yearly outage: 2008 - 2018

Paluel
PWR 1300 MW series : 20 Units
6 P4 / 14 P’4 units
Connection to the grid: 1985 - 1994
2nd ten-yearly outage: 2005 - 2013
3rd ten-yearly outage: 2015 - 2023

Penly
PWR 1450 MW (N4) series : 4 units
Connection to the grid: 1996 - 1999
1st ten-yearly outage: 2008 - 2010
Flamanville
Gravelines
Chooz
Cattenom
Nogent
Fessemheim
Chinon
Civaux
Dampierr
e
St-Laurent
Belleville
Bugey
Le Blayais
Golfech
St-Alban

PWR EPR series :
The first unit currently being built
Cruas
Tricastin
Full series: built after a few years of
operation of the first of the series
 I&C unlikely to be exactly the same
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Approx. 80% of electricity production
Nuclear Power Plants at EDF, in United
Kingdom
From British Energy (part of EDF S.A.)

CGR :
410 MW : 4 Units
Connection to the grid : 1976 – 1977
520 MW : 2 Units
Connection to the grid : 1983 - 1985
585 MW : 4 Units
Connection to the grid : 1983 - 1984
615 MW : 4 Units
Connection to the grid : 1988 - 1989

PWR 1190 MW : 1 unit
Connection to the grid: 1995

PWR EPR series :
7 potential sites
 I&C unlikely to be exactly the same
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Approx. 20% of electricity production
On-going I&C-related activities at the NPP’s, in
France
 Regarding EPR

in Flamanville :
 Architecture design validation, Allocation of functions, Safety Assessment …

In UK
 Discussion with HSE, NII : EPR I&C Design acceptance
 Regarding the 58 existing plants in France

3rd ten-yearly outage for the 900 MW in progress :
 e.g. Modernization of the Rod control System : PLCs and FPGA-based modules.

1st ten-yearly outage for the 1450 MW in progress : No I&C modification

3rd ten-yearly outage for the 1300 MW :
 Aging & Obsolescence studies : “health” assessment of the current I&C systems (2007-2008)
 Plant Performance studies : operation, maintenance, availability, power generation….
 Feasibility studies (technique, budget, delay) for some important/critical systems (according
to the strategic objectives) : in progress
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Planning of the 1300 MW ten-yearly outage
20.06
Phase
1
Orientation
2
20.07
20.08
Projet DDV
3
Phase
Stratégique 4
5
20.09
2011
2012
2013
2014
2015
2016
2017
J1
J2
Généralisation
Revue APS M2C
Clôture Lot suite
GPR Réexamen
OVCC 1300
Revue M2C
Rénov. CC
Etudes stratégiq
ues
Décisions Directoires
J0-18
J0-9
Finalisation D
6
J0
Etudes de Réalisation VD3
7
Phase
réalisation
2010
8
9
10
e-DIM
TTS
12 m. Mini
Intégration Parc
Cahiers des charges
ACHATS
validation lots achats
Etudes réalisation
REX
J0-33
Documentation Exploitation
Réalisation
Doc Exploit 13
Processus
ASN
14
15
16
17
18
19
20
Examen de
Conformité
de
Réalisation
6
J0-12
Lettre EDF DDV
ASN
Approb. Modifs logicielles J0-27
Lettre DPI
VD3 1300
lettre périmètre du lot
GPR Orientations
Déclaration à l'ASN de l'ensemble des modifs
DA disponible
J1+12
Avis ASN sur
rapport d'examen
Rapport de Sûreté P4 P'4
GPR Thématiques
GPR Réexamen
GPR Clôture
21
TTS
Principes de Définition duPréparationRéalisations
du
des contrôles
l'ECOT
Contour
Programme
sites et corrections
22
Présentation à l'ASN
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Etudes Correctives
Strategic objectives regarding NPPs at EDF
 Achieve maximum plant useful life
 Current
 When
 Not
planned lifetime for existing plants: 40 years
possible and cost-effective, extension to up to 60 years
all plants will be extended beyond 40 years
 Maintain safety
 Increase plant performance
 Increase
7
generation capacity
 Improve
availability and reliability
 Improve
operation and maneuverability
 Reduce
O&M costs
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Preparation of a ten-yearly outage
 The engineering team's basic questions
 For
the system X, is the "y" ten-yearly outage an ageing limit and the
renewal an obligation?
 Or
with which maintenance conditions is it possible to reach the "y+1" tenyearly outage?
 If
the renewal is an obligation, which technological solutions, or amplitude
of refurbishment is needed?
 To answer these questions a project with two phases is started
 Equipment
 Studies
ageing observation phase
to identify the possible scenarios for renovation
 Preparation
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20 - 22 May 2009
of a global action plan 5 years before outage
IAEA TWG-NPPIC Meeting
The I&C Ageing Observation phase
 Operating experience
 Failure rate of modules
 Maintenance costs
 Generation losses due to equipment
 Significant safety incidents and safety-relate events
 Visual equipment inspection on-site
 Identification of spare parts inventories
 Number and sensibility to obsolescence's
 Anticipation's study of identified ageing problems
 Industrial support of the manufacturer
 Study of operating environment of control equipment (ventilation, power
supply, cables etc.)
 Evaluation of the available margins
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
I&C Technologies in the NPPs in France
1300
900
Turbine
Control
Electronic
components (REC
70)
REC 70
Analog
Automation
Analog electronic
components
(8720 & 9020 series)
9020 series
Logic
Automation
Electromagnetic
relays
COTS PLC
(Controbloc)
Reactor
Protection
Control
Room
Systems
Electromagn. Relays
Analog electronic
components
Digital eq. (MicroRec)
N4
EPR
Digital equipment.
(MicroRec)
Digital equipment
(P320)
DCS (Contronic E)
DCS (T2000)
COTS DCS (Micro Z) Specific PLC (SCAP)
Specific 1E digital
system (SPIN)
Conventional panel
Conventional panel
Computerized aids
Computerized aids
DCS (Contronic E)
DCS (T2000)
Specific 1E PLC (CS3)
Specific 1E digital
system (SPIN-N4)
Specific F1A digital
system (TXS)
Computerized CR
Computerized CR
Conventional panels
(Remote & back-up)
Conventional panels
(Back-up. )
 Global initial strategy regarding “critical” I&C systems:
10

Spare part of components

Long term agreement with the suppliers : competencies and tools
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
900 MW : Rod Control system Modernization
 Partial modernization (obsolescence and reliability issues) : Change the
automation part (small analog/discrete modules). Keep the instrumentation
(1E) and the power modules (gripper coil current generator).
Systèmes extérieurs
 New I&C System :

Supervision Locale
RIC
Computation
Turbine /
GCT
KIT
SIP
S. de Cde
Relayage
RPR
RGL
Position
 (Non-1E system) : COTS
fil à fil
« passerelle
sécurisée »
Mesures
E.A.
 PLCs
fil à fil
 networks
 Supervisor

Slave cycler
 Time constraints (1ms)
RGL
Pilotage
e/s DMA+LC
Supervision Locale
RGL commande
DMA+LC
DMA
Réseau
inter-automate
éternet redondé
RGL
Cycleurs
fil à fil
(commande)
RGL
Chassis Puissance
GF X
GF Y
(dans ESPs)
GF Z
GM
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Supervision Locale
RGL position
modbus/ RS485
(supervision, recalage)
Cycleur
Cycleur
Cycleur
Cycleur
Cycleur
Cycleur
(dans ESPs)
CP0 : 4 cycleurs
CPY : 6 cycleurs
Armoire de
Maintien
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LT
passerelle
 FPGA-based modules
 Site validation in progress (Tricastin)
e/s LT
BM
relais
dispositif mobile
paramétrage local
automate ou cycleur
1300 MW : Reactor Protection, Rod Control &
Nuclear Instrumentation Systems
 Context :

Increase in Performance : more sensors, more computation power…

Some aging & EMI problems
 Modernization studies for the 3 systems on progress:

RPS :
 Partial modernization at modules level :
 « Clone of MC 6800 » and increase in clock rate
 New FPGA-based modules with functions implemented in VHDL
 Partial modernization at computation level with a (1E) COTS : keep the global architecture,
the I/0 racks and the cabling

RCS :
 Total modernization : a new I&C Systems

NIS:
 Partial modernization at modules level
 Partial modernization at computation level : keep the I/0 racks and cabling
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
1300 MW : Logic Automation - Controbloc
 Context :

New functionalities may be added, but not enough margin

No problem (aging, obsolescence…) for the next ten years

Some improvement at the system level can be considered (reliability…)
 Studies in progress

Addition of new I&C systems (PLCs):
 Connection to the existing (proprietary) Controbloc : development of a “bridge”
 interface between the existing CAD tool and the CAD tool of the new PLC
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
Anticipation of a possible modernization at the next ten-yearly outage (at the
interface/connector level)

Re-design of some modules (FPGA-based solution to be considered)

Development of a validation tool for logic application, with a high coverage rate
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
1300 MW : Analog Automation
 Turbine control system
 µREC
: Obsolescence, modification for power generation improvement
 Renovation of the system
 REC
70 : Long term agreement OK, modification for power generation
uprate
 Choice between modification/renovation
 General Control system :
 9020
: long term agreement OK, functional improvement
 Modification may need to change the system
 µZ
: long term agreement OK, functional improvement
 Modification of the application only
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Control Room modernization – Enhancement
of the exploitation
 1300 MW Control Room Modernization

Supervision : new supervisor, improvement of the alarm management…

Monitoring : digital recorders, Core 3D_monitoring…

Human factor impact
 INTEP Projects : modern Information Technologies Integration

EPO project : Smart applications to support operation and diagnosis
 E.g. : use of wireless sensors for monitoring activities (e.g. : vibration data collection)

TELL Me project : Smart help for field operations
 E.g. : tagging-out and lining-up for outage

R&D-A Project : New solutions for outage management and maintenance/logistics
preparation
 E.g. audio& video monitoring, shared real time information (dashboards)
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Studies Focusing on FPGA Technology
 Context :

Microprocessor-based system are more & more complex : no more dedicated to
industrial domains
 Needs for suitable I&C products
 FPGA (or ASIC) might be a cheaper, simpler solution than PLC (µProcessor)-based
solutions
 For new products as well as for replacing specific components/modules of I&C systems
 IEC 62566 : a new standard for Complex Electronic Components (incl. FPGA)

Available in 2011
 R&D studies, in the IEC 62566 context :

Cloning a component : « 6800 IP » suitable for 1E application

« FPGA-based » modules
 Develop a method for the qualification of FPGA-Based technology
16
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Recommendations
to IAEA
Items to be considered
Items to be considered for Maintaining the
current I&C Systems
 Obsolescence and Ageing of I&C equipment (analog equipment, digital
equipment, cabling, connectors…)

Management of spares, long-term storage, verification
 Approaches to facilitate replacement : E.g., portability of applications on “easily”
replaceable platforms

Understanding of ageing mechanisms and factors, in particular for current
integrated circuits and electronic boards

Estimation / Extension of remaining lifetime (obsolescence, aging mechanisms…)
 Long-term management of I&C expertise

Ageing workforce, inadequate existing documentation, new digital technologies
tend to become obsolete rapidly…

Identification and documentation of key knowledge, including I&C design basis

Means to retrieve, structure and use documented knowledge for new generation
 Guidance for Maintening existing I&C Systems
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Safety Related Issues to be considered - 1
 Regulatory uncertainties regarding “new” technologies

ASICs / FPGAs : for replacement, for new I&C systems

Wireless technologies : May avoid / limit need for new cabling for additional
monitoring measurements. Could be used to assist and integrate the work and
actions of local teams

Data communication networks (including fieldbus)

Cyber-security
 Guidance for a safe use of new technologies
 Safety evaluation of COTS I&C equipment

I&C platforms, “smart” devices… (we are at the limits of the acceptable complexity)

What is common to, and can be shared by, all / most countries?

What can be shared with other safety-aware industries?
 Common requirements and assessment criteria : international
consensus to be reached (regulatory requirements)
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20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Safety Related Issues to be considered - 2
 Evaluation of the overall impact of I&C modernization on plant safety
 New
technologies may introduce new failure modes
 The
limits are nearly reached in term of complexity (architecture,
components…)
 Diversity
 New
may increase complexity
technologies may also have beneficial effects
 E.g., improved equipment reliability, improved fault tolerance
 Representation
of digital systems in probabilistic models
 Realistic
consideration for assessment of software (system + application) :
Verification and Validation (tests) as complementary tools
 Realistic
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20 - 22 May 2009
consideration of software common cause failures
IAEA TWG-NPPIC Meeting
Items regarding Improvement of Plant
Performance (1)
 Power uprate

New technologies for reduction of uncertainties in measurements to increase power
output while maintaining safety margins
 Improved plant availability

I&C equipment critical to plant availability
 Identification
 Dependability assessment
 Evaluation of effects on plant availability
21

Reduction of likelihood of human errors

Improved fault tolerance

Improved actuator lifetimes

Improved diagnostics
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Items regarding Improvement of Plant
Performance (2)
 Improved equipment reliability

Identification of wear & ageing mechanisms, and of I&C contribution

Predictive, condition-based equipment maintenance, early fault detection

Practical operation & maintenance decision aids from raw information

Additional information for improved equipment reliability
 Improvement of thermal efficiency

Detection of thermal losses
 Reduction of operation & maintenance costs
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
Fleet monitoring, remote access to information by centralized experts

Information System, aids aimed at each local Operation Branch (Control,
Maintenance, etc)

Homogeneous control room systems
20 - 22 May 2009
IAEA TWG-NPPIC Meeting
Optimization of Costs and Uncertainties of I&C
Projects
 Guidance for good utility requirements
 Guidance for analogue - digital transition
 Guidance to minimise costs and uncertainties of I&C modernisation
projects
 Guidance for evaluation of costs, risks, benefits of different I&C
modernization options
 Including
 Over
maintenance of statu-quo
the remaining lifetime of the plant
 Consideration
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20 - 22 May 2009
also of capital budget and license renewal constraints
IAEA TWG-NPPIC Meeting