Getting Another 20 Years from Your Simulator Hardware 15 January 2018 Barnard Gagnon Tung Nguyen 2018 Power Plant Simulation Conference (PowerPlantSim’18)
Getting Another 20 Years from Your Simulator Hardware
15 January 2018
Barnard GagnonTung Nguyen
2018 Power Plant Simulation Conference (PowerPlantSim’18)
Topics
• L3 MAPPS Brief Overview
• Introduction
– Hardware and software obsolescence
– Upgrade challenges/objectives
• Panel Instruments and I/O System
• A/V System
• Computer Systems
• Power Supply/Protection
• Conclusions
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 2
L3 MAPPSBrief Overview
About Us
L3 TechnologiesHQ: New York City38,000 employeesUS$10.5 billion (2016)4 Business Segments
© 2017 L3 MAPPS. All rights reserved. 4
Aerospace Systems
38%
Electronic Systems
28%
Comm. Systems
20%
Sensor Systems
14%
Global NPP SimulationFootprint
(celebrating 45 yearsof innovation)
L3 MAPPSHQ: Montreal
3 Markets: Naval, Power Gen., Space
Control Systems & Simulation
Solutions Overview
1/17/2018 © 2017 L3 MAPPS. All rights reserved. 5
5
Full Scope Simulators Severe Accident Simulation Simulator Modifications Classroom Simulators Part-task Trainers
Engineering Simulators Learning Modules
L3 MAPPS Power Systems and Simulation
SIMULATIONCANDU Plant Computers
CONTROLSSystem Knowledge Modules Learning Simulators
Introduction
Introduction
• Most US NPP simulators were originally built in 1970-80’s
– Simulator (Control Room and Auxiliary) panels, instruments, I/O system and models
– Upgrades generally performed incrementally based on budget considerations and most urgent needs
– Simulator maintainers face many challenges over time, particularly obsolescence
• What could go wrong?
• Is it easy to repair/replace?
• Other challenges?
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 7
Introduction
• Hardware obsolescence over time
– Failures more frequent
– Instrument repairs become difficult
– Sometimes plant “borrows” simulator’s spare parts
– Replacement parts are difficult to find
OEM no longer in business
Supply/support from OEM no longer available
Other sources can be difficult to find (e.g. eBay)
$$$
– Computers/computer parts obsolescence
– Interface cards no longer available (e.g. PCI vs. PCIe)
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 8
Introduction
• Software obsolescence issues
– Operating Systems (O/S) not supported on newer computers/servers
e.g. Windows XP cannot run on new DELL computer
Hardware drivers not available
– Third-party software doesn’t run on newer O/S
Compilers (e.g. Compaq Fortran, Microsoft Visual Studio, etc.)
Centralized database (e.g. Microsoft SQL Server)
– Third-party software licenses no longer available from OEMs
– Antivirus not updated on older platform cyber security concerns
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 9
Simulator Maintenance and UpgradesChallenges/Objectives
• During simulator operation/training
– Minimize down time due to simulator failures (hardware and software)
– Improve recovery time
– Quick equipment/computer replacements
– Minimize and reduce simulator maintenance cost, including spare parts
– Simplify deployment of new simulator software
• During simulator upgrades (minor or major)
– Minimize simulator outage time
– Optimize testing and validation time
– Minimize cost
• Ultimate goal
– High simulator availability and reliability!
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 10
Panel Instrumentsand I/O System
Panel Instruments and I/O System Upgrade Approaches
• Several strategies
– I/O System replacement
Incremental upgrade to free-up legacy I/O components for spare parts
Full I/O system replacement
– Re-wiring
Spaghetti?
Documentation existence and accuracy
Brittle wires
– Instruments replacement
Availability?
Re-engineer
Spare parts managementPPS 2018 © 2018 L3 MAPPS. All rights reserved. 12
L3 MAPPS’ Approach for I/O Systems: Compact I/O
• Many distributors worldwide• Large user base: industrial, building automation, marine, etc. • Wide variety of I/O modules• High density modules• Low power consumption• Passive ventilation• I/O controller has the capability of running user-programmable
control logic (i.e. synchroscopes)• Advanced diagnostics• Orchid® Input Output to manage I/O communication
I/O System MCR Panels
• Quick replacement of failed modules
• Minimize down time
• Minimal or no re-wiring
• Inexpensive modules
– No need to repair
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 13
Compact I/O System Advantages
• Provides very clean setup and wiring
• Requires very little space
• Flexible
• Expandable
• Easy to maintain
• Negligible noise production
• Compact I/O solutions have been deployed by L3 MAPPS on
– Full Scope Simulator projects
– Simulator Upgrade projects• High reliability
– Mean Time Between Failures (MTBF) from 20 to 40 years
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 14
Instrument wiring retained as-is, maximize use of ribbon cables
Minimized simulator downtime during changeover Junction modules are passive
Krško (Slovenia) Simulator – I/O System Replacement
Legacy
Junction Modules
New Design
I/O System
Simulation Server
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 15
Diablo Canyon (USA) Simulator - I/O System Replacement
Instrument wiring retained as-is (minimized re-wiring errors) Minimized simulator downtime during changeover Adapters are passive
RTP I/O Adapter Cards(DO, DI, AO, AI)
BEFO
RE
Edge
Con
nect
or
Device Hood
Connector
AFTE
R
Edge
Con
nect
or
Device Hood
Connector
I/O Module
I/O ModuleI/O Module
LegacyNew Design
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 16
Re-Engineered Panel Instruments
• If feasible, source original instrumentation
• Obsolescence and cost are key drivers for re-engineering
– Retain the same look-and-feel
• Spare parts
– Request spare parts early
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 17
Incandescent Lamps
• Incandescent lamps tend to fail on a regular basis and are expensive over time
• Replace with LEDs
– Match the physical fidelity (color and intensity)
– Reduce failure rates significantly
Reduce frequency of DORT testing
– Less power consumption
Reduce the sizing of the power supplies
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 18
Annunciators
• FSS using LCD screens for annunciators windows
• Training needs assessment to be performed when physical fidelity and human factors deviations exist between the reference unit and the simulator
Tihange 1 (Belgium) Simulator
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 19
Dual-Unit Simulator Control Room Panels
• Reactor 1 desk fully instrumented
• Reactor 2 desk using hybrid solution
– Instruments for controls
– LCD screens for monitoring instruments and displays
Heysham 1 (UK) Simulator
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 20
Other Considerations
• Use of instrument connectors
– Quick removal, repair and installation
– Increased initial installation cost
– Reduce downtime due to re-termination of instruments
• Spare parts strategy
• Identification of single points of failure
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 21
A/V System
A/V System
• Orchid® Multimedia Manager
– Runs on Windows computers
• Recording of audio and video feeds individually
– Debriefing (i.e. playback) synchronized with the simulation or standalone
• Use of Commercial Off-The-Shelf equipment
– IP Cameras and microphones
– Digital encoders for DCS screens
– Can connect to existing cameras(digital or analog)
– Interface to audio mixer using virtual sound card
• Reduces need for special hardware (e.g. joystick)
– Camera controls through user interface
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 23
Computer Systems
Virtual Machine
• Two servers connected to a common disk array (RAID configuration)
• Each server capable of simultaneously running a virtualized Full Scope Simulation and a backup/development machine
– DCS, PPC and more…
• Rapid switchover with no loss of data
• Countermeasure for hardware and operating system obsolescence
– Virtual machines can be installed on newer platforms with minimal effort and cost
• Used for upgrades while keeping the previous simulation server ready in case of problems
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 25
Computer Systems - Other Considerations
• RAID controllers (software or hardware)
– Avoid loss of precious data
• Performing incremental upgrades
– Simulation environment and tools
– Third-party software (compilers, SQL database, O/S, etc.)
• Mid- and long-term upgrade strategy
– Plan/allocate budget in advance
– Be proactive
• Offsite backups
• Availability of ready-to-go/pre-tested devices and computers
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 26
Power Supply/Protection
Power Supply/Protection
• Use of Uninterruptable Power Supply (UPS) and Power Conditioner
– Main focus on computers/servers and I/O system
– Avoid power transients on sensitive electronic equipment
– UPS allows graceful shutdown of computers and avoid potential data corruption
– Configure automatic notifications of power failures (e.g. email, SMS, etc.)
– UPS and Power Conditioner solutions can be combined
PPS 2018 © 2018 L3 MAPPS. All rights reserved. 28
Conclusions
Conclusions
• We looked at
– Panel Instruments and I/O System
– A/V System
– Computer Systems
– Power Supply/Protection
• Important to be forward-looking and plan for potential failures
• As much as possible, use equipment with large user community (i.e. not only in the nuclear business)
• Maximize the use of COTS components
– However, re-engineered instruments might be necessary
• Virtualization makes simulator more hardware independent
• Provision wisely for spare parts
– Obsolescence / repair / minimize simulator downtime
• Availability of ready-to-go/pre-tested devices and computersPPS 2018 © 2018 L3 MAPPS. All rights reserved. 30
Thank YouL3 MAPPS
8565 Côte-de-LiesseMontréal, Québec, Canada
H4T 1G5
Tel: +1 (514) 787-4999 Fax: +1 (514) 788-1442
Web: www.L3T.com/MAPPSLinkedIn: L3 MAPPS
L3 MAPPS8565 Côte-de-Liesse
Montréal, Québec, CanadaH4T 1G5
Tel: +1 (514) 787-4999 Fax: +1 (514) 788-1442
Web: www.L3T.com/MAPPSLinkedIn: L3 MAPPS
2018 Power Plant Simulation Conference (PowerPlantSim’18)