I&C Status at EDF & Recommendations to IAEA

I&C Status at EDF&

Recommendationsto IAEA

I&C Status at EDF&


IAEA TWG-NPPIC Meeting20-22 May 2009

Vienna

Patrick Salaün – EDF

EDF Nuclear Power Plants

EDF Nuclear Power Plants

Studies concerning the I&C Systems

20 - 22 May 2009 IAEA TWG-NPPIC Meeting3

PWR 900 MW series : 34 units 6 CP0, 18 CP1, 10 CP2 unitsConnection to the grid: 1977 - 19883rd ten-yearly outage: 2008 - 2018

PWR 1300 MW series : 20 Units6 P4 / 14 P’4 unitsConnection to the grid: 1985 - 19942nd ten-yearly outage: 2005 - 20133rd ten-yearly outage: 2015 - 2023

PWR 1450 MW (N4) series : 4 unitsConnection to the grid: 1996 - 19991st ten-yearly outage: 2008 - 2010

PWR EPR series : The first unit currently being built

Full series: built after a few years of operation of the first of the series

I&C unlikely to be exactly the same

Nuclear Power Plants at EDF, in FranceNuclear Power Plants at EDF, in France

Approx. 80% of electricity production

GravelinesGravelines

ChoozChooz

CattenomCattenom

NogentNogent

FessemheimFessemheim

St-LaurentSt-Laurent

BellevilleBelleville

BugeyBugey

St-AlbanSt-Alban

CruasCruas

TricastinTricastin

GolfechGolfech

Le BlayaisLe Blayais

CivauxCivaux

ChinonChinon

FlamanvilleFlamanville

PaluelPaluel

PenlyPenly

DampierreDampierre


Nuclear Power Plants at EDF, in United KingdomNuclear Power Plants at EDF, in United Kingdom

From British Energy (part of EDF S.A.)

CGR :

410 MW : 4 UnitsConnection to the grid : 1976 – 1977

520 MW : 2 UnitsConnection to the grid : 1983 - 1985



PWR 1190 MW : 1 unitConnection to the grid: 1995

PWR EPR series : 7 potential sites

I&C unlikely to be exactly the same Approx. 20% of electricity production


On-going I&C-related activities at the NPP’s, in FranceOn-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


Planning of the 1300 MW ten-yearly outagePlanning of the 1300 MW ten-yearly outage

20.06 20.07 20.08 20.09 2010 2011 2012 2013 2014 2015 2016 2017

Phase 1 Projet DDV

Orientation 2 OVCC 1300

3 Rénov. CCPhase

Stratégique 4 Etudes stratégiques

5 Décisions Directoires J0-18 J0-9

6 Finalisation D J0 J1 J2Généralisation

7 Etudes de Réalisation VD3 e-DIM TTS 12 m. Mini Intégration Parc

8 Cahiers des charges9 ACHATSvalidation lots achats10 Etudes réalisation

REX

Doc Exploit 13 Documentation ExploitationRéalisation14 ASN15 Approb. Modifs logicielles J0-27

Processus 16Déclaration à l'ASN de l'ensemble des modifs

ASN 17 DA disponible18 lettre périmètre du lot J1+12Avis ASN sur

rapport d'examen 19 GPR Orientations Rapport de Sûreté P4 P'420 GPR ThématiquesGPR Réexamen GPR Clôture

21 Réalisations des contrôlesTTS sites et corrections

22 Présentation à l'ASN Etudes CorrectivesContour

J0-12

J0-33

Préparation du Programme

Principes de l'ECOT

Définition du

Clôture Lot suiteGPR Réexamen

Phase réalisation

Examen deConformité

de Réalisation

Lettre EDF DDV

Lettre DPI VD3 1300

Revue M2C

Revue APS M2C


Strategic objectives regarding NPPs at EDFStrategic objectives regarding NPPs at EDF

Achieve maximum plant useful life

Current planned lifetime for existing plants: 40 years

When possible and cost-effective, extension to up to 60 years

Not all plants will be extended beyond 40 years

Maintain safety

Increase plant performance

Increase generation capacity

Improve availability and reliability

Improve operation and maneuverability

Reduce O&M costs


Preparation of a ten-yearly outagePreparation 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" ten-yearly 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 ageing observation phase

Studies to identify the possible scenarios for renovation

Preparation of a global action plan 5 years before outage


The I&C Ageing Observation phase 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


I&C Technologies in the NPPs in FranceI&C Technologies in the NPPs in France

Turbine Control

Analog Automation

Logic Automation

Reactor Protection

Control Room Systems

900 1300 N4

Electronic components (REC 70)

Analog electronic components(8720 & 9020 series)

Electromagnetic relays

Electromagn. Relays

Analog electronic components

Conventional panel

Computerized aids

REC 70

Digital eq. (MicroRec)

Digital equipment. (MicroRec)

9020 series

COTS DCS (Micro Z)

DCS (Contronic E)

Specific PLC (SCAP)

COTS PLC (Controbloc)

DCS (Contronic E)

Specific 1E PLC (CS3)

Specific 1E digital system (SPIN)

Specific 1E digital system (SPIN-N4)

Conventional panel

Computerized aids

Computerized CR

Conventional panels (Remote & back-up)

EPR

Digital equipment (P320)

DCS (T2000)

DCS (T2000)

Specific F1A digital system (TXS)

Computerized CR

Conventional panels (Back-up. )

Global initial strategy regarding “critical” I&C systems:

Spare part of components

Long term agreement with the suppliers : competencies and tools


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).

New I&C System :

Computation

(Non-1E system) : COTS

PLCs

networks

Supervisor

Slave cycler

Time constraints (1ms)

FPGA-based modules

Site validation in progress (Tricastin)

900 MW : Rod Control system Modernization900 MW : Rod Control system Modernization

Systèmes extérieurs

RGLCycleurs

RGLChassis Puissance

Supervision LocaleRGL commande

MesuresE.A.

DMA

e/s DMA+LC

Supervision LocaleRGL position

Supervision LocaleRIC

(dans ESPs)CP0 : 4 cycleursCPY : 6 cycleurs

S. de CdeSIPKITRelayage

RPRTurbine /

GCT

Réseauinter-automateéternet redondé

DMA+LC LT

fil à fil

fil à fil(commande)

Armoire deMaintien

CycleurCycleur

CycleurCycleur

CycleurCycleur

modbus/ RS485(supervision, recalage)

relais

GF X

GM

BM

GF Y

GF Z

e/s LT

RGLPosition

passerelle

dispositif mobile

paramétrage localautomate ou cycleur

RGLPilotage

fil à fil

(dans ESPs)

« passerellesécurisée »


1300 MW : Reactor Protection, Rod Control & Nuclear Instrumentation Systems 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


1300 MW : Logic Automation - Controbloc1300 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

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


1300 MW : Analog Automation1300 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


Control Room modernization – Enhancement of the exploitationControl 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)


Studies Focusing on FPGA TechnologyStudies 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



Items to be considered


Items to be considered for Maintaining the current I&C SystemsItems 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


Safety Related Issues to be considered - 1Safety 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)


Safety Related Issues to be considered - 2Safety 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 may increase complexity

New 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 consideration of software common cause failures


Items regarding Improvement of Plant Performance (1)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

Reduction of likelihood of human errors

Improved fault tolerance

Improved actuator lifetimes

Improved diagnostics


Items regarding Improvement of Plant Performance (2)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

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


Optimization of Costs and Uncertainties of I&C ProjectsOptimization 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 maintenance of statu-quo

Over the remaining lifetime of the plant

Consideration also of capital budget and license renewal constraints

I&C Status at EDF & Recommendations to IAEA

Documents

mw series

mw n4 series

series ic unlikely

pwr epr series

ic status

ic modification3rd

units connection

current ic systems