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MAJOR SIMULATOR UPGRADE FORDUNGENESS B
15 January 2020 2020 Power Plant Simulation Conference (PowerPlantSim’20)Gregory Zakaib, Proposals Manager
• L3 MAPPS Inc. | Power Systems and Simulation
Presented at
PowerPlantSim’20
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Outline
• Background• Simulator Upgrade Project
– Project Overview– Two-phase Deployment– Schedule– Challenges/Strengths/Successes
• Conclusions
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source: EDF Energy
BACKGROUND
Major Simulator Upgrade for Dungeness B
3PRESENTATION TITLE (USE INSERT > HEADER & FOOTER TO EDIT FOR ALL SLIDES)
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EDF Energy’s Current Nuclear Sites
• L3Harris supported facilities– Stations
– Dungeness B– Hartlepool– Heysham 1– Hinkley Point B– Sizewell B
– Other Training Facilities– Campus– Nuclear Power Academy (Barnwood)
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Dungeness B Power Station
• Dungeness B was first commercial AGR power station to be constructed
• The £89 million contract was awarded in August 1965 to Atomic Power Constructions (APC), a consortium backed by– Crompton Parkinson– Fairey Engineering– International Combustion and Richardsons– Westgarth and Co
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Dungeness B Power Station
• Two Advanced Gas-Cooled Reactors (AGRs)– Graphite moderated / CO2 primary coolant – 4 x boiler / gas circulator units – Pre-stressed concrete pressure vessels– Single control room for both reactors
• Commercial Operation– Unit 1 (R21) 1983– Unit 2 (R22) 1985
• Current operating lifetime up to 2028
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Dungeness B Power Station Common Control Room (CCR) Simulator
• Original simulator and training team based at Oldbury Training Centre in Gloucestershire from the mid-1980s
• Simulator moved into a purpose-built building at Dungeness B site in 1999
• Unit 1 and Common plant systems simulated• Unit 2 plant systems not simulated• Hardware based on Silicon Graphics (SGI) IRIS
servers and Hytec Electronics CAMAC I/O– SGI ceased operations in 1989– Hytec ceased operations in 2016
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Legacy SGI Computers Legacy CAMAC I/O System
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Dungeness B Power Station CCR Simulator
• 10 years Plant Life EXtension (PLEX) approved until 2028
• EDF Energy recognizes importance of simulator– Reliability– Maintainability– Latest Simulation Technology
• Simulator Upgrade project funded by PLEX program– Goal: Modernize simulator and ensure it can fulfil its
mission until plant end of life
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source: EDF Energy
SIMULATOR UPGRADE PROJECT
Major Simulator Upgrade for Dungeness B
PRESENTATION TITLE (USE INSERT > HEADER & FOOTER TO EDIT FOR ALL SLIDES)
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Simulator Upgrade Contract Award Criteria
• Commercial– Compliance (conditions of
contract and tender instructions)– Supplier financial status– Pricing and payment terms– Warranty– After sales service
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• Technical– Competence (capability and
qualifications)– Previous project experience,
capability and qualifications– Risk management– Innovation (technical solution and
project flexibility)
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Simulator Upgrade Contract
• EDF Energy awarded contract to L3Harris in December 2016• Contract extended in early 2017 to include replacement of legacy CAMAC I/O system
– Additional work had impact on original planned project tasks/schedule, however change in scope accommodated without impacting any key delivery dates
• Project broken down into two distinct phases
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Phase 1• New computer system• Rehost Unit 1 configuration• Unit 1 I/O system replacement• Classroom simulator
Phase 2• Unit 1 configuration updated with new
core/RCS/SG models• New Unit 2 configuration• Unit 2 panels and desk
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Phase 1 – New Computer System
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Phase 1 – Rehost
• New operating systems and third-party software
• Orchid® simulation environment
• Rehost legacy simulation software to Orchid®– Source code – GFLOW models converted to Orchid® Modeling
Environment graphical models– Database– Initial conditions– Training exercises (scenarios)– Triggers (conditions)– Etc.
• New soft panels
• Converted tutor diagrams
• Stimulated/simulated external systems
• Upgraded A/V system
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Phase 1 – Orchid® Instructor Station
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• Control and monitor all aspects of simulator and trainee performance
• Fully graphical user interface with standard Windows features e.g. drag and drop, window resizing, zoom, pan, etc.
• Highly configurable (e.g. toolbars, plant parameters, feature behaviors, etc.)
• User-defined windows layout
• Client/server application
• On-line PDF user manuals
• Simulation control and maintenance functions (freeze, unfreeze, store, restore, speed-up, slow-down, DORT, etc.)
• Replay scenarios and operator actions (synchronized with the other systems such as Orchid® Multimedia Manager, etc.)
• Insertion of plant component and system malfunctions, instrument overrides and local operator actions
• Direct access to modeling schematics, active schematics and virtual (soft) panels
• On-the-fly creation of active schematics and virtual panels
• Multiple operating modes i.e. instructor, operator, engineer and student
• Built-in exam security
• Focuses on automation and data collection– Create/edit graphical scenarios– Monitor, record and trend any parameter– Monitor and track operator performance– Scenario-based Testing and Training
(SBT2) – Generate training performance records
and reports based on ANSI/ANS-3.5 requirements
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Phase 1 – New Soft Panels
• Scope– Unit 1 Desk – Unit 1 Panels– Common Panels– Back Panels– Backup/Emergency
Panels– Sync Trolley
• Available from Orchid® Instructor Station
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Phase 1 – Tutor Diagrams + External Systems
• Tutor Diagrams– Legacy tutor diagrams converted to Orchid® Graphic
Editor displays using L3Harris’ pre-existing conversion tool, with fine adjustments performed as necessary– Identical look-and-feel as legacy tutor diagrams (no tutor
learning curve)– Available from Orchid® Instructor Station
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• External Systems– ATOS Digital Plant Control System (DPCS)
– Stimulated (complete) DPCS in full scope simulator– Simulated alarm list with Orchid® Control System in
classroom– POLARIS Plant Monitoring System (PMS)
– Partially simulated PMS HMI with Orchid® Control System in full scope simulator and in classroom
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Phase 1 – Upgraded A/V System
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• Hardware– 6 analog cameras and microphones retained– 2 new digital encoders (4 channels each) – New A/V server
• Software– Orchid® Multimedia Manager
– A/V recording and playback– Time-synchronized with the simulator for
synchronized audio-video playbacks– Connectivity with debriefing room– Preview of all cameras in a mosaic display
for monitoring at all times– Stores files using industry-standard “AVI”
format
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Phase 1 – Unit 1 I/O System Replacement
• Hardware– Legacy CAMAC I/O system replaced with new
Beckhoff EtherCAT compact I/O system– 1-to-1 I/O points
• Software– Orchid® Input Output
– Provides online diagnostics– Hardware and communication failure
indications sent to Instructor Station (i.e. Simulator Confidence)
– Conversion from engineering units to electrical units
– Panel sleep
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Phase 1 – Unit 1 I/O System Replacement
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Before After
Legacy CAMAC I/O controllers replaced with interface to mate existing
I/O wiring and connectors to new BeckhoffI/O installed on DIN rails
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Phase 1 – Classroom Simulator
• 5 Student Workstations (capability to run independent simulations)
• 1 Standard Orchid® Touch Interface Bay– Utilized for testing at L3Harris– Delivered to Dungeness B during
Phase 2
• Mobile Instructor Station with Orchid® Instructor Station
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Phase 2 – Dual-Unit Simulation Strategy
• Capability to operate Unit 2 stand-alone or in conjunction with Unit 1 to simulate complete power station• Similar strategy implemented by L3Harris at Heysham 1• Benefits of dual-unit simulator
– Provides very representative and realistic control room environment especially important for plant with common control room
– Enables training of full shift crews following plant processes and procedures– Enhances shift crew teamwork– Enhances control room communication skills while directing actions to be performed on a specific unit (communication
more complex than before)– Allows opportunity for control room personnel to prioritize tasks to perform on training scenarios affecting both units
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Phase 2 – New Models
• Unit 1 Legacy Updated – New Reactor Core Model
– Comet Plus™ Reactor Core Model / Orchid® Core Builder – New Boiler and Reheater Model
– ANTHEM™ / Orchid® Modeling Environment– New Gas Circuit Model
– ANTHEM™ / Orchid® Modeling Environment– Boundary Interfaces
– Feedwater, startup vessel, main steam– RCS gas bypass circuit
• New simulator load for Unit 2 created– Unit 1 used as starting point and updated to match R2
conditions
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Phase 2 – Unit 2 Panels and Desk
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Phase 2 – Unit 2 Panels and Desk
• Full Hard Panels solution– Replace existing Unit 2 Panel mockup with new structure and new operable instruments– Retain Unit 2 Desk structure / add new operable instruments
• Best physical fidelity/realism (i.e. look-and-feel)• Enable most effective training
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Existing Unit 2 Panel mockup New Unit 2 Panel Instruments
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Phase 2 – Unit 2 Panels and Desk
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PHASE I (Rehost and I/O Replacement) Rehost Design Rehost Development and Integration Rehost FAT I/O Design I/O Prototype Build and Test At Dungeness I/O Production Build and Factory Test Install at Dungeness
Phase 1 SAT Support EDF Training (Remotely from L3M)
Phase 2 (Model Updates + Unit 2 Panel / Desk)Unit 1 Model Development and IntegrationUnit 1 Model FATUnit 1 Model SATUnit 2 Model Development and IntegrationUnit 2 Model FATUnit 2 Panel/Desk DesignUnit 2 Panel/Desk DevelopmentUnit 2 Panel/Desk Integrated FATSite Work: Panel Disassembly / New Panel Install
Unit 2 Panel/Desk and Model Update
2017 2018 2019Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q1
2020Q4 Q1 Q2 Q3 Q4
• Contract award: December 2016• In Service: November 2019
Project Timeline
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Ph 1 Unit 1 Training
Ph2 Takeover
P2 Unit 1 Training
BAR Sched Template (QTR)
2017201820192020
StartFinishQ1Q2Q3Q4Q1Q2Q3Q4Q1Q2Q3Q4Q1
PHASE I (Rehost and I/O Replacement)PHASE I (Rehost and I/O Replacement)
DesignMon 1/16/17Fri 3/10/17 Rehost Design
Development and IntegrationMon 2/6/17Fri 8/4/17 Rehost Development and Integration
FAT Mon 6/5/17Fri 8/25/17 Rehost FAT
DesignMon 4/24/17Tue 8/8/17 I/O Design
Prototype Build and Test At DungenessWed 8/2/17Tue 10/10/17 I/O Prototype Build and Test At Dungeness
Production Build and Factory TestWed 10/11/17Wed 1/31/18 I/O Production Build and Factory Test
Install at DungenessMon 2/5/18Fri 2/23/18 Install at Dungeness
Phase 1 SATMon 2/26/18Fri 3/23/18Phase 1 SAT
Support EDF Training (Remotely from L3M)Mon 3/26/18Fri 6/22/18 Support EDF Training (Remotely from L3M)
EDF Energy Take-Over - Phase 1Thu 8/30/18Thu 8/30/18
Phase 2 (Model Updates + Unit 2 Desk/Panels) Phase 2 (Model Updates + Unit 2 Panel / Desk)
Development and Integration1/1/18Fri 8/31/18Unit 1 Model Development and Integration
FAT10/22/1811/9/18Unit 1 Model FAT
Unit 1 Model SAT
1/1/19Unit 2 Model Development and Integration
Unit 2 Model FAT
DesignMon 3/26/18Fri 7/13/18Unit 2 Panel/Desk Design
DevelopmentFri 7/13/18Wed 4/24/19Unit 2 Panel/Desk Development
FATWed 4/24/19Tue 5/14/19Unit 2 Panel/Desk Integrated FAT
Old Panel Disassembly / New Panel InstallationMon 6/17/19Fri 6/28/19Site Work: Panel Disassembly / New Panel Install
SAT Unit 2 Panel and Model UpdateMon 7/1/19Fri 7/12/19 Unit 2 Panel/Desk and Model Update
Phase 2 - Take Over CertificateFri 10/18/19Fri 10/18/19
``
Sheet1
Task NameDurationStartFinish
PHASE I (Rehost and I/O Replacement)
Rehost
Design40 daysMon 1/16/17Fri 3/10/17
Development and Integration130 daysMon 2/6/17Fri 8/4/17
FAT 60 daysMon 6/5/17Fri 8/25/17
I/O Replacement
Design77 daysMon 4/24/17Tue 8/8/17
Prototype Build and Test At Dungeness50 daysWed 8/2/17Tue 10/10/17
Production Build and Factory Test81 daysWed 10/11/17Wed 1/31/18
Site Work
Install at Dungeness15 daysMon 2/5/18Fri 2/23/18
Phase 1 SAT4 wksMon 2/26/18Fri 3/23/18
Support EDF Training (Remotely from L3M)13 wksMon 3/26/18Fri 6/22/18
EDF Energy Take-Over - Phase 10 wksThu 8/30/18Thu 8/30/18
Phase 2 (Model Updates + Unit 2 Desk/Panels)
Model Update
Design76 daysFri 5/18/18Fri 8/31/18
Development and Integration126 daysFri 8/31/18Fri 2/22/19
FAT76 daysFri 1/18/19Fri 5/3/19
Unit 2 Desk/ Panels
Design80 daysMon 3/26/18Fri 7/13/18
Development204 daysFri 7/13/18Wed 4/24/19
FAT15 daysWed 4/24/19Tue 5/14/19
Site Work
Old Panel Disassembly / New Panel Installation10 daysMon 6/17/19Fri 6/28/19
SAT Unit 2 Panel and Model Update10 DaysMon 7/1/19Fri 7/12/19
Phase 2 - Take Over Certificate0 daysFri 10/18/19Fri 10/18/19
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Challenges
• Schedule – New I/O system upgrade scope added, without impacting the final delivery date of
Phase 1
• Behavior of retained legacy models and higher fidelity Orchid® replacement models– Increased the need for discussions and workshops with plant experts
• Maintenance of multiple configurations – Synchronizing field updates from Phase 1 (rehost) training into Phase 2 during
model development– Synchronizing changes between Unit 1 and Unit 2 configurations during the
deployment lifecycle
• EDF Energy support stretched between testing in Montreal and supporting training at Site– Overcome by deferring non-critical items to later phases– Provision of training load at EDF for remote support– Use of automated testing features of Orchid® Instructor Station to reduce face-to-
face testing time*
• Obsolescence of panel instruments– 3D printed many devices to replicate look-and-feel of originals
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*Automated Testing
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Recorded Data
Alarm Logs
Simulator Actions
Operator Actions
Scenarios
SBT2 • Collated & organized• Saved in 1 folder• Can be zipped
and/or protected• Saved in common
formats (.doc, .xls, .pdf).
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Project Strengths/Successes Expressed by EDF Energy
• Performance– EDF Energy pleased with project progress – L3Harris’ processes, policies and procedures in all areas of operation (Project
Management, Contract Management, Quality Assurance, Engineering) are professional
• Cooperation & Communication– Cooperation and communication between L3Harris and EDF Energy on highest
standard and allowed project to progress to meet customer requirements
• Flexibility– L3Harris’ flexibility in scope change management and commercial
arrangements allowed EDF Energy to focus on project with responsive L3Harris team
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source: EDF Energy
CONCLUSIONS
Major Simulator Upgrade for Dungeness B
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Conclusions
• Project completed successfully to EDF Energy’s satisfaction• Dungeness B Simulator now on modern and easy-to-use/maintain
platform: Orchid®– New high-fidelity models provide most realistic responses and easier to
maintain using L3Harris’ state-of-the-art graphical modeling tools– Orchid® Core Builder– Orchid® Modeling Environment
• Obsolete computers and I/O system no longer threat to training program • Enhanced training capabilities with classroom simulator• Upgraded simulator sustainable until the end of power station life• New Unit 2 simulation, desk and panels integrated with Unit 1 simulator
provides most representative and realistic control room environment– Allows training on dual-unit scenarios – not possible before
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Major Simulator Upgrade for�Dungeness BOutlineBackgroundEDF Energy’s Current Nuclear SitesDungeness B Power StationDungeness B Power StationDungeness B Power Station Common Control Room (CCR) SimulatorDungeness B Power Station CCR SimulatorSimulator Upgrade ProjectSimulator Upgrade Contract Award CriteriaSimulator Upgrade ContractPhase 1 – New Computer SystemPhase 1 – RehostPhase 1 – Orchid® Instructor StationPhase 1 – New Soft PanelsPhase 1 – Tutor Diagrams + External SystemsPhase 1 – Upgraded A/V SystemPhase 1 – Unit 1 I/O System ReplacementPhase 1 – Unit 1 I/O System ReplacementPhase 1 – Classroom SimulatorPhase 2 – Dual-Unit Simulation StrategyPhase 2 – New ModelsPhase 2 – Unit 2 Panels and DeskPhase 2 – Unit 2 Panels and DeskPhase 2 – Unit 2 Panels and DeskProject TimelineChallenges*Automated TestingProject Strengths/Successes Expressed by EDF EnergyConclusionsConclusionsSlide Number 32