Development of digital I&C system in HTR-PM

Shi Guilian

CTEC

2

1. CTEC Profile

2. HTR-PM DCS Development Overview

3. HTR-PM Safety DCS Development

4. HTR-PM NC DCS Development

5. Conclusions

CONTENTS

3

HollySys

1.CTEC Profile-Organization

10

departments

708

employees

GMs

Go

v . P

roje

ct

HR

FIN

AN

CE

AD

MIN

EN

GIN

EER

ING

R&

D

PR

OD

UC

TIO

N

Lin

e

MA

RK

ET

ING

PR

OJE

CT

A

dm

in

QU

ALIF

Y

Gov. Functional Business BD Centre

Providing full-life-cycle and end to end digital I&C system solution and service to NPPs

4

1. CTEC Profile-products

5

2014Independent 3rd party V&V certificate on

FirmsysISTEC

2013

design/manufacturing license on 1E panels &civil 1E

electric equipment

NRC preliminary evaluation on Firmsys

Function safety certificate by SIL3SIL3

2011

3rd party V&V evaluation by TUV

CMMI L4

EDF supplier qualification for electric , I&C

TUV

CMMI L4

2010

Design license on civil nuclear safety

electric equipment

Manufacturing license on civil nuclear

safety electric equipment

ISO14001/OHSAS18001

ISO14001

OHSAS18

001

2009 enterprise standard Q/GLHJ

2008 CMMI L3 CMMI L3

2006 ISO9001 ISO9001

1. CTEC Profile-Certificates

6

Projects covering all the in-service NPPs and majority new builds, the

reactor types including CPR1000,ACPR1000, M310, EPR, HTR, CNP, CEFR, etc.。

1. CTEC Profile- Projects

CPR1000： 14 unit DCS

•HYH 1-4、ND 1-4、YJ 1-4、

FCG 1-2

•13 delivered to NPP

•5 under commercial operation

ACPR1000：4

•2 ：Integration in CTEC（YJ56)

•2 ： : in contract negotiation

(HYH56) (Big step, FirmSys )

•NC-DCS 、 Safety-DCS、BOP

I&C , DCS simulator in FSS 、

Emergency system etc.

No. Project Contract time

1 HTR-PM digital RPS prototype 2009.09

2 HTR-PM digital RPS supply 2009.09

3 HTR-PM non-safety DCS prototype 2010.04

4 HTR-PM non-safety DCS supply 2010.07

5 HTR-PM DEH(Digital Electric Hydraulic Control System) 2012.09

7

安全级DCS

非安全级DCS

汽轮机控制系统

DEH

全厂一体化DCS

2. HTR-PM DCS - contracts

UNIT Safety DCS NC-DCS

System Design SW V&V

NI designpurchaser

Contract NI BOP design

DEH purchaser

Equipment development

Safety Equipment qualification

Basic / Detail design

Manufacture, integration, test.

Technical support

8

2. HTR-PM DCS - contracts

9

2. HTR-PM DCS - roadmap

First engineering prototype ，then real system manufactured

Same software and hardware with the actual DCS

Safety DCS: 1:1 engineering prototype

NC DCS: verify key design, DCS Architecture, new control logic, MMI ect.

With almost all level2 configuration and 30% of level1 input/output

10

2. HTR-PM DCS - roadmap

The safety-DCS equipment is dedicated for HTR-PM Safety-DCS .

11

3.7 核级DCS（FirmSys）应用业绩

2. HTR-PM DCS – system structure

HTR-PMSafety DCS

HTR-PMNC-DCS

ACPR1000Safety DCS YJ56

ACPR1000NC-DCS YJ56(U5 and U7)

ControlStation

28 45 46 50

Cabinet 38 108 91 58

Input and output signal

3458 13679 9846 11000

Operator station

Total 204 in MCR *22 in RSS *2

4 in cabinet *2

135 ENG

16 16

Display 300 200 640*2 900

Safetyfunctions

14 RTS3 ESFAS

21 RTS7 ESFAS

2. HTR-PM DCS R&D-System Scale

HTR-PM Safety DCS : simplified and reliable ；

HTR-PM NC DCS: enriched, completed functions, of similar scale to a ACPR1000 unit.

三. Engineering Prototype development Process

NPP and system requirements

Computer-based system requirements

Computer system requirements

protection system specificationPAMS specification

Safety protection system specification

Safety signal isolation cabinet specification

Other components

Computer system design

SW requiremen

ts computer system

integration

HW requiremen

ts

SW design

HW design

SW implementa

tion

HW realization

protection cabinet

design

Structure design of

cabinets and modules

cabinet assembly

Safety Software VV

Qualify control

Continuous running test

environment test

EMC test

seismic test

Function test

Protection cabinet X, protection cabinet y

channel monitoring cabinet, safety display device

signal isolation cabinet, safety control cabinet, ESFAC

Design Development Qualification

routine test reportcontinuous running test

reportEMC test report

environmental test reportseismic test report

protection system periodic test device, protection system integration test device

En

gin

eerin

g p

roto

typ

e in

teg

ratio

n

HW system design

HW integration

Pro

tectio

n sy

stem

specific

atio

n Manufacturing of cabinets and

modules

3. HTR-PM safety-DCS – overall requirement

1、Function requirements:

Signal isolation distribution, reactor trip, engineering safety

features actuation, MCR ventilation, post accident data monitoring

2 、Structure requirement：4 channels redundancy, 2 layers of 2/4

voting structure, with consistency logic, 2 diversity group in each

channel.

3、main performance:

Response time: delay from monitoring variable signal input to

ESFAS/trip actuation signal output(ESFAC side) ≤300ms

Analogue acquisition precision：0.1%

3. HTR-PM Safety DCS R&D – System Structure• Signal isolation device

• Signal process device x/y

• logic voting device x/y

• PAMS display

• Channel monitoring device

• Safety actuation device A/B

• MCR ventilation control

• Signal isolation cabinet

• Protection logic x/y cabinet

• Channel monitoring cabinet

• MCR ventilation cabinet

• Safety actuation cabinet

• Safety display unit

2014/12/3016page

。Including: Isolation, IO signal , control &

protection arithmetic equipment, safety

display and control equipment, safety

communication network, communication

gateway, power supply, cabinets. 42 HW

equipment, 15 mechanical equipment, 13

Software , 70 in total

HTR-PM Safety-DCS

Hardware(42)

主控/通信 (5 种)

IO/调理 (3种/2种)

电源

(2 种)

转接 & 切换 & 继电器

& 监视 (30 种)

机柜(5种)

机箱、面板(10种)

工程师站软件

(6 种)

嵌入式软件

(7种)

Mechanical

(15 )

Software(13)

2. HTR-PM DCS – equipment List

第 17 页

3. HTR-PM Safety DCS Development-Equipment Technical Features

In accordance to safety I&C standard: SW design: HAD102/16, IEC-

60880 HW design: IEC-60987

Deterministic software：No Commercial OS 、break is not used in the

normal running. Fixed Memory allocation, Fixed task scheduled

Reliability design and analysis through the whole process

Point-to-point communication technology

High-coverage self-diagnostic design technology

safety information display design technology without commercial OS.

3. Safety DCS – Software V&V

◇Responsible by INET；◇V&V implemented in all phases of safety SW

life cycle;◇in accordance with IEEE 1012, L4(the highest) ;

◇executed under the principle of threeindependence

Stage Nun Status

Basic design 186 closed

SoftwareReq.

16 closed

Software architecture

Design 18 closed

Software detail design

21 closed

Unit test 44 closed

System test 8 closed

Total 293 closed

19

2013年10月 2014年8月

机柜制造Cabinet manufacturing

机箱制造Rack manufacturing

PCB制造PCB

manufacturing

PCBA制造PCBA

manufacturing

鉴定试验执行EUT集成

EUT integrati

on

鉴定试验程序test procedure

测试装置研发test

device R&D

试验室评估Lab evaluation

鉴定试验先决条件检查Qualificati

on test pre-

condition check

基准试验

Baselinetest

环境试验

Environment test

EMC试验

EMC test

抗震试验

Seismic test

鉴定试验总结报告

Test report

现场监查Field

inspection

现场见证Field witness

现场见证Field witness

现场见证Field witness

现场见证Field witness 专家评审会

Experts evaluation

第三方制造3rd party manufacturer

第三方试验室3rd party lab

CTEC

说明remark：

专家会&NRO监管expert panel &NRO

标准分析Standard analysis

专家评审会Experts

evaluation

鉴定方案qualification

plan

鉴定大纲qualification

program

专家评审会Experts

evaluation

EUT设计 EUT design

鉴定设计阶段Design

鉴定分析阶段Analysis

鉴定准备阶段Preparation

鉴定执行阶段Implemtation

鉴定总结阶段Sum-up

Equipment Qualification Process

3.HTR-PM Safety DCS

IEEE323

IEC60780

GB/T12727

IEEE344

IEC60980

IEC 61000-4

IEC 61000-6

TR-107330

IEC 60068-2

环境试验environment test

EMC试验EMC test

抗震试验seismic test

GB/T13625

HAF.J.0053

GB/T 17626 GB/T4824

GB/T9254

TR-107330

GB/T2423

RG1.209 RG1. 180 RG1.100

RCC-E

TR-107330

基准试验baseline test

RG1.209

20

2014-3-24环境试验通过

Environmental testpassed

2014-5-28EMC试验通过

EMC test passed

2013-9-24鉴定大纲专家会

Qualification plan expert review

2014-7-8抗震试验通过Seismic test

passed

Environmental test

EMC test

Seismic test

3. HTR-PM Safety DCS - Equipment qualification Progress

Basic design

DF1 DF2 DF3 CFC ManufactureSystem test

Installation

Engineering prototype design, manufacture and qualify

Finished task

On going task

Not started task

Engineering prototype qualification tests finished.

Go all out to ensure the actual system delivery!

3. HTR-PM Safety DCS – Progress

2015 SEP.

Function requirements：

Non-safety DCS is used to monitor operation ,control and analyze data of reactors,

BOP, CI, DEH, and DAS,.

Main performance：

Min. control cycle≤50ms

SOE time resolution≤ 1ms,inter-station SOE time resolution≤ 2ms

System availability≥99.99%

4. HTR-PM non-safety DCS R&D-Overall Requirement

23

4. HTR-PM NC-DCS-system structure

NC-DCS

Control station

45

Cabinet 108

IO 13679

Operatorstation

13

Display 200

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

大数据量管理

中间件与软总线

OPC开放接口

HS1000

HS2000

MACS

SMARTPRO

MACS

SCADA

HOLLiAS

工业以太网+PROFIBUS总线

SM系列低功耗高可靠性模块

面对对象的实时数据库

微内核结构与伸缩性应用

专业化DCS

大容量系统结构

32位QNX

IEC61131-3

多域结构

矢量图形OOD/OOP

集成系统

国际合作

基于WINDOWS的组态软件功能块、梯形图和计算公式多重系统自诊断在线下装系统全冗余ARCNET令牌网+CAN总线

实时DOS-RTX

全汉字界面

点阵图形

VME总线HS2000

CAS

PC工程定制开发

DAS5000

国家军工质量保证体系

ISO9001

CMMI L3

HOLLiAS产品发展路线图

HOLLiAS-N

2007

4. HTR-PM NC-DCS-HOLLiAS-N

HOLLiAS-N：

Software NPP specialized function：

HMI system compatible with nuclear Human factor engineering

standard

Alarm system compatible with IEC 62241

Digital procedure

Specialized graphic symbols ,function block and SPDS calculation.

Authorization Management customized to NPP operator shift.

Hardware：

Metal shell，increase anti -Seismic and EMC capability

Environmental adaption intensified

NPP specialized hardware: priority logic module, etc..

第 25 页

NC-DCS prototype：

In the end of 2011, the prototype was delivered to INET.

Actual NC-DCS:

Integration of software and hardware finished in this month. After 9

months of system factory test and factory acceptance test , The System will

be ready to be delivered in Jul. 2015

4. HTR-PM NC DCS- Progress

2015 JUL.

5. Conclusions

2009 technical meeting 2011 Mr.zhang Zuoyi and Wu yulong visit CTEC

2012 System integration 2014 Seismic test passed

HTR-PM DCS has been under execution for 5 years( 2009-2014) . It has taken CTEC

150 man/year so far. With close cooperation with INET, Chinergy and Shanghai

Electric, CTEC overcame difficulties, like iterative design, voluminous customization

work, new technology, and lacking of drawings. However, the accomplishment of

the planned milestones prepared CTEC for the following work in HTR-PM DCS

1. The 1ST integrated DCS, including safety DCS, non-safety DCS, DEH

supplied by Chinese supplier. Rod control system and DEH are integrated

in non-safety DCS. Simplified interface, integrated platform, and easy to

use and maintenance

2. CTEC obtained knowledge of 4th generation HTR-PM digital I&C, key

design technology, and riched its DCS products by participation in HTR-

PM. HTR-PM Safety DCS project provided valuable experience for CTEC’s

development and application of FIRMSYS, a safety protection control

system platform.

3. The qualification solution by customized HTR-PM safety DCS prototype

helps simply safety DCS design, V&V, qualification and safety review of

the actual system, but results in some problems in system upgrade and

maintenance. With the satisfactory application of FIRMSYS in 1000mw

PWR and platform qualification , the future HTR-PM safety DCS could be

provided based on a qualified safety DCS platform.

5. Conclusions

Thank you for your attention