Applications & Benefits of Engineering Simulators

Transcription

1 2018 Power Plant Simulation Conference (PowerPlantSim 18) Applications & Benefits of Engineering Simulators 17 January 2018 Michael Chatlani Vincent Gagnon

2 Topics Introduction Engineering Simulators Applications L3 MAPPS Enabling Simulation Technologies Main Challenges & Solutions Benefits Examples of Engineering Simulators Conclusions PPS L3 MAPPS. All rights reserved. 2

3 Introduction

4 Operator Training Simulators: Mission Accomplished! L3 MAPPS has been providing Nuclear Power Plant Operator Training Simulators since 1973 PPS L3 MAPPS. All rights reserved. 4

5 Operator Training vs. Engineering Simulator Operator Training Simulator Full main control room hardware replica Focused on plant operator training Engineering Simulator Desktop-based with virtual (soft) panels and operator HMI Focused on other applications to support plant activities Source: AREVA Source: AREVA Same Plant Functionality PPS L3 MAPPS. All rights reserved. 5

6 Why consider Engineering Simulators? Operator Training Simulators Reality Large investment for utilities and other organizations Utilized mainly to train plant operators to prevent human performance errors Current simulator modeling and physical fidelity and realism are well suited for engineering purposes Technology is such that computing power is no longer a constraint Why not leverage the Operator Training Simulators investments for other purposes? Why Risk a plant startup delay due to engineering design issues? Risk an unplanned trip due to poor control room human factors engineering? Test systems in open loop when they can be tested in closed loop with realistic plant response feedback? Engineering simulators are made possible for Nuclear New Builds as well as Existing Nuclear Power Plants PPS L3 MAPPS. All rights reserved. 6

7 Engineering Simulators

8 Applications Plant Design Verification and Validation (V&V) Nuclear New Builds I&C Controls (Closed Loop) DCS & Plant Process Computer HMI (Operator Displays) Alarms System Process (System Design and Equipment Characteristics) Plant Modifications V&V Existing Nuclear Power Plants Main Control Room Human Factors Engineering/Research Safety Assessment Studies (LOCA, SGTR, Inadvertent Dilution, PSA, etc.) Training Regulator Plant Personnel (Engineers, ERO, Management, etc.) Plant Procedures (Operating, Maintenance, Commissioning, etc.) Development, V&V and Dry-Run Severe Accident & SAMGs Analysis Licensing Support Simulator V&V etc. PPS L3 MAPPS. All rights reserved. 8

9 Example: Early Identification of Plant Design Issues Engineering Simulators can and should be used to assist in plant/dcs engineering and other applications L3 MAPPS NNB simulator developments have contributed to the early identification (and resolution) of 1,000s of plant design issues Example of distribution of discrepancies on one NNB simulator project: 45% Non-safety DCS 9% Safety DCS 26% Process to DCS Interface Data 3% 5% 12% Non-safety DCS Calibration Modeling and Calibration PPS L3 MAPPS. All rights reserved. 9

10 Main Challenges Plant design changes constantly Especially true for Nuclear New Builds/DCS How to easily identify what needs to be modified on the simulator when the plant data changes? Engineering design change process is slow Most Operator Training Simulators are over-utilized not leaving enough time for activities not related to operator training Plant departments (other than Training and Operations) do not know about the potential, capabilities and benefits of simulation PPS L3 MAPPS. All rights reserved. 10

11 Solutions Simulation models match one-to-one plant design documents/drawings Graphical models and real-time graphics allow for prototyping, quick changes and immediate feedback Automated process to update the simulator DCS controls and HMI (DCS Translation Process) Strong configuration control and management tools designed for graphical simulation tools Educate plant personnel on possible simulation applications PPS L3 MAPPS. All rights reserved. 11

12 L3 MAPPS Enabling Simulation Technologies Real-Time Graphical High-Fidelity Models Object-Oriented & Data Import Capability Easy to Use Modeling Tools Real-Time Operator HMI Displays Object-Oriented & Data Import Capability Easy to Use HMI Simulation Tools Real-Time Graphics Soft Panels Active Schematics Object-Oriented Easy to Use Graphical Tools Versatile I/O System Solution Closed Loop Testing Capability Easy to Use I/O Diagnostics & Monitoring Tools PPS L3 MAPPS. All rights reserved. 12

13 Simulation vs. Plant Design: One-to-One Containment Reactor RCS BOP Electrical I&C Plant Documents Repository (SharePoint) Plant Documents synchronized with Simulation Models Simulation Models synchronized with Plant Documents Plant System Models (Orchid ) PPS L3 MAPPS. All rights reserved. 13

14 DCS Translation Process Plant DCS Input Files HMI Pages Simulator Files HMI Pages Controls Orchid Controls Plant Database Translator Tool Simulator Database PPS L3 MAPPS. All rights reserved. 14

15 Configuration Control & Management Plant Data Plant design data can be referenced and tracked in Orchid Modeling Environment at schematic [system] or library object [component] level Live connection with SharePoint Easy navigation between plant design data and modeling schematics/objects Plant design data tracking can provide a snapshot of where plant data is used and which schematics/objects are affected by data updates PPS L3 MAPPS. All rights reserved. 15

16 Configuration Control & Management Schematics, libraries and files versioning Version rollback capabilities Visual comparison feature for different versions of Workspaces Configurations Schematics Libraries Files PPS L3 MAPPS. All rights reserved. 16

17 Benefits Quantitative Protect the health and safety of the public and plant workers (e.g. injury, radiation exposure, death, etc.) Prevent equipment failure and damage (e.g. turbine, main feedwater pump, etc.) Depending on equipment, could result in millions of dollars in repairs plus loss of generation Prevent unplanned plant shutdowns and extended plant outages Direct costs associated with refueling outages can exceed $800,000 USD per day Loss of generation can exceed $500,000 USD per day [source: Oliver Wyman research (global management consulting firm) as reported by Power Engineering in 2009] Early identification and correction of deficiencies is significantly less costly than during commissioning Return on investment of a relatively inexpensive Engineering Simulator can be significant PPS L3 MAPPS. All rights reserved. 17

18 Benefits Non-Quantitative Inherent (built-in) simulation features such as speedup/slowdown, automated testing, charts, data collection, etc. Enhance quality/user friendliness of plant engineering products Better acceptance of plant modifications by operators Enhance quality of Operator Training Simulators Testing and validation beyond standard testing Increase credibility with regulators, outside organizations and peers (NRC, INPO, WANO, other utilities, etc.) Industry best practices Company public opinion by preventing a plant event Same technology used for Operator Training and Engineering Simulators PPS L3 MAPPS. All rights reserved. 18

19 Examples of Engineering Simulators

20 Example: SNERDI CAP 1400 Engineering Design Analyzer (NNB) Shanghai Nuclear Engineering Research and Design Institute (SNERDI) CAP1400 Engineering Design Analyzer Used to Support CAP1400 engineering design activities Develop interfaces with third-party applications SNERDI put considerable effort into identifying a technology that would be well-suited to developing the Engineering Design Analyzer. We selected L3 s Orchid to help us meet our goals and we look forward to L3 s collaboration as we move into the development phase. Gu Guoxing, vice president of SNERDI PPS L3 MAPPS. All rights reserved. 20

21 Example: Olkiluoto 3 (EPR) Engineering Simulators (NNB) Source: AREVA AREVA EPR Design V&V (multiple copies) Used for Digital I&C design V&V o Interfaces o I&C functions o Normal operation o Defense in depth concept o Operating displays Systems design V&V Test plant operating procedures Dry-run commissioning procedures PPS L3 MAPPS. All rights reserved. 21

22 Example: Simulator for Human Factors Research Idaho National Laboratory (INL) Human Systems Simulation Lab (HSSL) Used to Test emerging technologies for their application in control rooms Prototype HMI displays and control room variations with operator-in-the-loop Source: INL PPS L3 MAPPS. All rights reserved. 22

23 Example: Simulator for Human Factors Research SNC-Lavalin Nuclear Enhanced CANDU 6 (EC6) Engineering Simulator Used to Develop and validate the new EC6 main control room Design and test programmable electronic systems (PES) and human-system interfaces Source: SNC-Lavalin Nuclear PPS L3 MAPPS. All rights reserved. 23

24 Example: Simulator for Human Factors Research Center for Advanced Engineering and Research - Center for Safe and Secure Nuclear Energy Advanced Configurable Main Control Room Simulator Used to perform critical experiments in the U.S. for Alarm systems Control room design Display navigation Development of human performance measures PPS L3 MAPPS. All rights reserved. 24

25 Example: Simulator for Safety Studies Source: AREVA AREVA L3 MAPPS simulation integrated with CATHARE (French advanced calculation code) used to study the behavior of pressurized water reactors in accident conditions Used to perform Plant engineering and emergency response training Operating procedures analysis and improvement System design modifications Preliminary safety analysis PPS L3 MAPPS. All rights reserved. 25

26 Example: Simulator for Plant Modifications/Operator Confidence Ameren Missouri Operator replacing analog feedwater controls with DCS (Siemens SPPA-T3000) Plant simulation attached to actual feedwater control cubicles to exercise the new DCS before DCS implemented on actual plant Combined system flagged numerous design issues which Ameren Missouri used to mitigate unintended problems with the DCS designer Simulation Computer I/O Modules SPPA T3000 HMI PPS L3 MAPPS. All rights reserved. 26

27 Example: Simulator for TSO Institut de Radioprotection et de Sureté Nucléaire (IRSN): TSO to French safety authority (ASN) SOFIA: Simulator for Observation of Functioning during Incidents and Accidents Used for Engineer training (from beginners to experts) (ASN, CEA, IRSN) Preparation of emergency response exercises Studies in support of safety evaluations System design modifications Preliminary Safety Analysis (EOPs, Nuclear Safety, Incidents & Events analysis, Post- Fukushima analysis, PSA, ) PPS L3 MAPPS. All rights reserved. 27

28 Example: Simulator for Nuclear Regulator National Regulation Authority Severe Accident Simulator (PWR) Developed in cooperation with Westinghouse for NRA Supports normal operations, transient events, Design Basis Accidents, Beyond Design Basis Accidents, Severe Accidents and actions to be taken by operators who experience the incidents Used to Train regulatory body personnel PPS L3 MAPPS. All rights reserved. 28

29 Conclusions

30 Conclusions Operator Training Simulators have been successfully delivered and utilized for decades to train plant operators Engineering Simulators can be utilized for a variety of other applications L3 MAPPS offers robust and mature simulation tools for both Operator Training Simulators and Engineering Simulators Engineering Simulators offer quantifiable and other benefits L3 MAPPS has extensive experience in delivering Engineering Simulators for different applications for Nuclear New Builds and Existing Nuclear Power Plants PPS L3 MAPPS. All rights reserved. 30

31 Conclusions Plant Operator Training Simulator Engineering Simulator Plant initial costs: in the billions of $ Plant operating and maintenance costs: in the 100s of millions $ per year for a fleet of nuclear reactors [source: EDF Energy] Simulator initial costs: in the millions of $ With the benefits of plant safety, personnel safety and costs savings, leveraging the Operator Training Simulator investment into a low-cost Engineering Simulator is a wise investment PPS L3 MAPPS. All rights reserved. 31

32 Thank You 2018 Power Plant Simulation Conference (PowerPlantSim 18) L3 MAPPS 8565 Côte-de-Liesse Montréal, Québec, Canada H4T 1G5 Tel: +1 (514) Fax: +1 (514) Web: LinkedIn: L3 MAPPS