4-Koehler-presentation 4 - Innovative Utilization of Smart i

8/3/2019 4-Koehler-presentation 4 - Innovative Utilization of Smart i

1/19

Innovative Utilization ofSmart Instrumentation at aNuclear Power Plant

Jeff Kerker, Bruce Power Design Team Leader

Terry Koehler, Lakeside Process Controls Project Technical Lead

Eddie Saab, Lakeside Process Controls Account Manager


2/19

IntroductionIntroductionIntroductionIntroduction

HX5 History

Basic System Operating Philosophy

Project Scope

Design Issues

Control Retrofit Challenges and Solutions

Results Achieved

Summary Lessons Learned


3/19

HX5 HistoryHX5 HistoryHX5 HistoryHX5 History

Steam hammers discovered and documented inHX5 drain lines. Station Condition Record (SCRs)were raised and Operating Experience (OPEX)was reviewed for similar events.

Various fixes applied that did not really addressthe root causes (e.g. boosters, time delay relays,valve changes, diffuser mods etc.)

Several steam hammer mechanisms wereoccurring, at various system conditions, thatconfused the investigations.


4/19

BasicOperatingPhilosophyBasicOperatingPhilosophyBasicOperatingPhilosophyBasicOperatingPhilosophy

P&ID Sketch for HP FW Heater Circuit


5/19

ProjectScopeProjectScopeProjectScopeProjectScope

Remove inverted loop in HX5 drains lines

Upgrade HX5 level control system identified as acontributing factor to various steam hammers.

Maintain independent, hard-wired turbine water induction

protection. (e.g. level switches)

Operator actions to be minimized.

HX5 to operate as per original design.

Modification required for the next unit outage. (7 months)


6/19

DesignIssuesDesignIssuesDesignIssuesDesignIssues

Where and how to bore the hole between thereheater drains pit and the condenser pit toeliminate the inverted loop?


7/19


Original Piping Configuration

Pit Bottom el. 571

Bruce B

Bruce A

CL

CL

Condensate Trench

HP Heater Drain Line 12 dia.

pipe el. 582-4pipe el. 582-3

Condenser Pit el. 578

CondenserCD1

pipe el. 592-0

36 Condensate Line

Ground Floor el. 591

pipe el. 592-6

pipe el. 583

el. 595-3

HP Heater45 35 28 35

Pit Bottom el. 571

pipe el. 585

el. 595-3

HP Heater

pipe el. 589-10

Ground Floor el. 591

HP Heater Drain Line 16 dia

HP Heater Drain Line in shallow trenchCondenserCD1

40 60 35

Condenser Pit el. 578

pipe el. 585-3

pipe el. 593-6


8/19


New Configuration

LCV relocated to East wall of CD1

CondenserCD1

Condensate Line Trench

Tunnel bored for relocated Drains Line

15

3762

HP Heater Drains Line reduced in sizefrom 16 to 12 dia.

HP Heaterel. 595-3

Condenser Pit el. 57836 Condensate Line

pipe el. 583

Pit Bottom el. 571

CL


9/19


The drains line contains saturated water at lowpower conditions. How do we deal with smallersecondary steam hammers caused by steambubble formation and collapse?



10/19

Significantly reduce size of possible steambubble by:

Reducing line length

Reducing line diameter

Continuous upward sloping line

Design the line to withstand 45,000 lbf steam

hammer at all locations.

SolutionSolutionSolutionSolution


11/19

FusedPipe SupportFusedPipe SupportFusedPipe SupportFusedPipe Support


12/19


The drains line contains saturated water at lowpower conditions. How do we deal with smallersecondary steam hammers caused by steambubble formation and collapse?

Upgrade pneumatic controls to Smart electronic.



13/19

ControlRetrofitChallengesControlRetrofitChallengesControlRetrofitChallengesControlRetrofitChallenges

Challenges

1. Analog and existing safety controls separate yetintegrated

Valves to integrate with existing safety logic from

existing level switches / pump starters Only one wire pair to be run from controller to control

valves

Controller required to sense the state of the safety logiccircuits to ensure bumpless transfer and avoid fast

transients which could cause water hammer

2. Hot commissioning time extremely limited one try only


14/19

ControlRetrofitSolutionControlRetrofitSolutionControlRetrofitSolutionControlRetrofitSolution

Deaerator and Dump Valves

New valves have DVC 6000PD, integrated solenoidsand junction box

On loss of power to the solenoid, positioner air supply isblocked and actuator air bled to achieve fail position

Through HART signal (3rd variable configured for supplypressure), trip of solenoid can be detected by controllerenclosure equipment

Allows for controller tracking mode to be engaged anddisengaged based on the state of the solenoid to avoidreset windup and unbalanced transfer

Smart positioner also allows position feedback and onlinevalve diagnostics (Performance Diagnostics)

Old DA Valve

Solution1. Smart utilization of Smart Equipment

New DA Valve


15/19


Controller Enclosure

A. ABB Micromod MC53000B Dual LoopController

Had internal software already verified byBruce Power to meet the requirements ofCATIII

Was used in the control room and henceoperators were familiar with operation

B. Valve Position Indicators

C. Rosemount 333U Triloops

Used to extract HART signals for valveposition and positioner air supply pressure

D. MC53000 Analog Expansion Board

Used to receive analog signals ofpositioner air supply pressure

E. Line Break Detection LEDs

Solution2. Smart utilization of Smart Equipment

A

B C

D

E


16/19


Complete hardware (all valves and controllerenclosure) in the loop simulation executedutilizing a high fidelity process model

Valve solenoids actuated by plant trip logic alsosimulated

Simulation used to verify individualcomponents worked correctly together tosatisfy the process requirements

Simulation was made an integral part of theFactory Acceptance test and ISO Quality

Program Simulation used to test response to expected

plant events (DA pump starts / switches, etc.)and abnormal events (pump failures / singlebank operation, etc.)

Solution3. Hardware in-the-loop Simulation


17/19


HP Feedwater Heater DA Pump Start-up

0

10

20

30

40

50

60

3:03:36

PM

3:04:19

PM

3:05:02

PM

3:05:46

PM

3:06:29

PM

3:07:12

PM

3:07:55

PM

3:08:38

PM

3:09:22

PM

3:10:05

PM

3:10:48

PM

ValvePositionCommand(%

Open)

-3

-1

1

3

5

7

9

11

Level(inchesaboveNWL)

DA Valve Position Command

Dump Valve Position Command

HX5B Level

Simulation

Actual

Simulation Allowed for control strategy

tuning and testing in asafe environment

Predicted many actualcases which were abnormalconditions which could notbe field tested

Predicted 5 minutes tostabilization on deaeratorpump start

Successful prediction ofevents tested in

commissioning giveconfidence that predictionsof behaviour underabnormal events aresimilarly accurate


18/19

Results AchievedResults AchievedResults AchievedResults Achieved

7 months from design

to implementation


19/19

Tunnels were bored, old piping was removed, newpiping installed, control system installed and coldcommissioned completed in 28 days.

Unit ran up with HX5A and HX5B in service with

no level alarms or transients. Only operator action required was to turn on the

drains pumps.

Small system disturbances occurred that were

later corrected with minor control changes andmodified system line-up. The next unit start-upconfirmed that these changes solved the problem.

Results AchievedResults AchievedResults AchievedResults Achieved

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