SCS January 2018 Using a commissioning simulator to secure plant schedule - SCS January 2018
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SCS January 2018
Using a commissioning simulator
to secure plant schedule
SCS January 2018
! Agenda © Copyright
TNPJVC
TAISHAN EPR simulators
Engineering Simulator overview
V&V using Engineering Simulator
Commissioning Tests on Simulator
TSN U1 Cold Functional Tests
TSN U1 pre Hot Functional BAS Tests
SCS January 2018
! Taishan EPRTM Simulators
• CORYS provides simulators to both TNPJVC and FRAMATOME
TNPJVC FRAMATOME
Operators training and licensing Commissioning risk mitigation
Taiffu Simulator Full Scope Simulator Engineering Simulator
• Copy of FA3 simulator for initial • RFT signed on Sept 27th 2014 • February 2015 1st version installed
operator training • Used full time for training • Four complete I&C update
• First version July 2010, updated • Successful completion of RO afterward for CFT and HFT
twice afterwards examination December 2014, SRO configuration
examination May 2015 • Simulated operational I&C
• Simulated I&C (spec level)
• Update forecasted after plant • Emulated Safety I&C
commissioning
• Emulated operational I&C
• Simulated I&C in early stage
• Emulated Safety I&C
• FSS project early stage use of simulated I&C before switching to
emulated I&C was fit to face upcoming commissioning challenges of
TSN EPR
• Design is still in progress, simulated I&C is more flexible than emulated
I&C
SCS January 2018
! Engineering Simulator Scope
Normal Operation: Full range from primary circuit opened to 100% power
Start-up, Shutdown, Load follow, House load, Reactor Trip…
Incidental and accidental transients
Steam Generator Tube Rupture
Loss Of Coolant Accident
Main Steam Line Break TSN Engineering Simulator
… Simulation • NSSS
Malfunctions & local actions scope • BNI
• CI
failures of systems, • Turbine
equipment, • Electrical systems
• HVAC limited to reactor building
breaks in pipes,
I&C • Simulated operational I&C
loss of power, • Emulated safety I&C
loss of I&C … • Simulated HMI
Out of scope
Operation from safety back-up panels
Severe accident
SCS January 2018
! Engineering Simulator Model
HMI
Models Thermal hydraulic: OM690: ALICES simulation
Inherited from DRAC and SPL (ALICES) Manual orders
Full Scope Simulator Annunciation
signalization
Containment I&C
TXS: emulator
T2000: ALICES simulation
Turbine control: ALICES
Rod controls Heat losses, Sensors Orders and
Breaks mass flow measurements check backs
and energy
Electrical
distribution
RCS
Power supply
Auxiliary systems
Thermal exchanges,
[B10], Water density Mass flow Conventional Island
Pressure
Neutronic model Enthalpy
COX3D exchanges
SCS January 2018
! Electrical and I&C simulation models SECTION 1
TS1
1110JA-
LGA
1120JA-
TA
99999 V
LGB
LGK LGP
LIA
Electrical systems distribution fully simulated
LKA LKF
CI
DIVISION 1 NI G
LHP
99999 V
LGF LHA
G
LJP
Main generator LIF
LJV
LJK
LJF
2H LJV
LJZ
LJA
12H
Emergency/Safety diesel generators
LAA
LKK LLA LLU
LKQ LLQ LOB
LKU LKP LLF LLP LOA LAK
Batteries
LVA
LVP
LVB
S YN L I S T E
LVF LOF
Non-safety class I&C: Simulated Siemens SPPA-T2000
PROS
Flexible for analysis/debugging, signals/parameters forcing, I&C logic modifications
Highly detailed, down to the allocation to cabinets and fallback values
Easy initial conditions maintenance
CONS cabinets are all synchronized, and I&C time transfers not in the
model
Safety-class I&C: Emulated FRAMATOME TXS
Functionality for on-line diagram and running code display,
parameters modification and implementation of hardware malfunctions
SCS January 2018
! Electrical and I&C simulation models
Black Boxes
Simulated with CORYS engineering toolbox ALICES (turbine and
generator control, Emergency Diesel Generator, Chillers…)
HMI: Simulated OM690
Same look and feel as the real system
SCS January 2018
! Engineering Simulator and V&V process
Import I&C database and HMI
after platform tests…
OR
… before platform tests
XML import
V-cycle TEC4 I&C Diagrams Simulation Diagrams
ES can been loaded with I&C databases using export/import tools
within 2 months.
So far 4 versions have been loaded for CFT and HFT
Latest design changes requested for site tests can be implemented
quickly on ES to support design, V&V or commissioning
~45 design modifications tested on ES to prepare HFT
SCS January 2018
! Engineering Simulator and V&V process
V&V activities for an I&C plant configuration are done at different level
• Site Commissioning
• Functional verification by Design
(Per System) • Engineering Simulator
(I&C and process model)
• Implementation verification by • Test Bay platform (I&C in cabinets or
I&C (Per System) emulator) (Per System)
Advantage of Engineering simulator versus other test means
Fully integrated I&C (safety and operational I&C, priority management, main black boxes) with plant HMI
(operating displays, procedures and alarms) and process model (closed loop)
Engineering simulator is the best test means that can provide FRAMATOME engineers with a
comprehensive feedback over the design and procedures quality
Simulated operational I&C is flexible and easy to use to correct/adapt until configuration is frozen. Very
useful to support design and standard V&V.
Limitations
Not a qualified tool – complementary of mandatory standard V&V and help to design
I&C performance (time responses) not representative of the real system
Are process models and simulated BBOX representative enough ?
Advanced tool requiring specific skills to work efficiently
SCS January 2018
! Engineering Simulator test objectives
The initial objective was commissioning risk mitigation by testing:
Normal operation procedures
Commissioning procedures, ~85 procedures chosen among:
Main plant Control loops
NSSS Fluid systems tests
Power supply loss (Main/Auxiliary grid transfer, Emergency Diesel Generator)
I&C division loss
→ Complex systems, harsh transients, deviation from normal operating range…
Engineering Simulator use was extended to:
Test of I&C transverse functions hardly testable on site
Particular Operating Rules (operation with loss of an I&C function)
Emergency Operating Procedures test
Human factor tests
Pretest and validation of I&C design changes before standard V&V
Control loops preliminary tuning
FRAMATOME Commissioning team training
Site tests preparation (hydro test, BAS test…)
SCS January 2018! REX - Benefits for Commissioning
Validate complex/risky commissioning test procedures
Test sequences, feasibility (I&C interlocks or spurious actions) and
ergonomics
Check component protection features and assess risk of equipment
damage
Identify the required I&C temporary modifications to be performed during
tests
Verify and validate I&C behavior together with the process
Complex scenario involving many I&C systems interfaces
Control loops behavior, Optimization strategy identification, and pre-tuning
Study fallback operations (reverse path, loss of control loops, …)
Secure schedule
Early findings of design/procedure flaws saves time on site
SCS January 2018! REX - Benefits for Commissioning
Training
Very efficient to train staff for good surveillance and avoiding human errors
Commissioning team CFT training and S1 Training
Mandatory Commissioning and Operation training for Startup Shift Engineers
Team building and Communication between disciplines
Design and commissioning engineers work out issues together
All disciplines are involved at some point (Process and Safety team, I&C,
Commissioning…)
On site support for design/commissioning teams
Design evolutions and Commissioning tests adaptation can be work out quickly
Efficient tool for troubleshooting
SCS January 2018! TSN U1 Cold Functional Tests
In November 2015, specific simulator activities were done by FRAMATOME
to finalize CFT preparation using a CFT I&C version.
The engineering simulator was used for different purposes :
Validation/redlining of Normal operation procedures used for CFT
performance,
Validation of TP ENS 21 hydro test procedure on the simulator,
Identification of all the I&C temporary modifications necessary to avoid
spurious actions or blocking actions from I&C during CFT Performance,
Validation/Tuning of some control loops used during CFT,
Training/qualification of Shift Supervisor Engineer on the simulator before CFT
(one week).
SCS January 2018! TSN U1 Cold Functional Tests
Meanwhile TNPJVC rehearsed CFT as well on the FSS
FSS I&C was unfortunately not in CFT configuration
Validation of emergency plan for over pressure transients during CFT
Elaboration of RBS start up and pressure control plan
Working on the risk of safety injection from diversification signals
Working on I&C interlocks
SCS January 2018! TSN U1 Cold Functional Tests
TSN Unit 1 Cold Functional Test (CFT) successfully completed on Jan.
27th, 2016
TNPJVC and FRAMATOME preparation proved to be complementary
No major problem of procedure identified during CFT
The temporary I&C modifications identified during preparation and on
simulator were exhaustive for hydro test (no concern during CFT
Performance)
Good behavior of the control loops optimized on simulator during CFT
performance.
SCS January 2018! TSN U1 preHFT BAS Tests
TSN Unit 1 preHFT NI Electrical Power Supply Change-over Tests (TP
BAS)
ANT/AST switchover
Switch-over to EDG (LOOP situation)
SBO Diesel Generator Black Start
Complex I&C logics with fully integrated plant
Many I&C forcing and scripting to conduct some tests
Potential risk for some equipment
3 BAS tests run on Engineering Simulator by FRAMATOME BAS test
coordinator
Run 1 and 2
Detect main I&C design issues for simulated systems
Debug simulator electrical model + BBOX issues (EDG/SBO/chillers/…)
Improve TP tests strategies and instructions
› In particular I&C forcing and scripts to be used during the tests (TCA)
Run 3 performed just before site tests
Rehearse critical tests taking into account latest site constraint (RPV closed)
Finalize and validate critical design change
Validate TP and TCA and gain confidence for upcoming site tests
SCS January 2018! TSN U1 preHFT BAS Tests
Tests completed successfully on TSN U1 on March 3, 2017
No major issues found on the ES simulation scope, mostly synchronization
issues due to I&C performance that could not be seen with simulated I&C,
and BBOX issues
Logic issues found on systems out of ES simulation scope (mostly HVAC)
and/or tests not rehearsed on ES
Despite known limitations (HVAC/BBOX), ES preparation was
highly valuable
SCS January 2018! Conclusion
Close partnership between CORYS and FRAMATOME engineering teams
allowed regular update of the simulator to stick to the design and meet plant
schedule
Engineering simulator allows us to
Discover and solve issues (I&C, procedures) before site tests
Gather different teams and improve communication and cooperation
Train our staff efficiently
A powerful tool to support design integration and commissioning
First full integration of I&C coupled with process before site tests
Detail design I&C simulation is very relevant for Commissioning
Even though it is not as representative as an emulator (time responses in particular)
A bug found in the simulator I&C logic or parameters is a bug on site as well…
…and the flexibility of the simulation allows to quickly sort it out
The exact I&C forcing to be done during Commissioning can be tested
Simulator most advanced users are now members of the Start Up Team
ES is a well known and recognized tool now on the TSN project
CFT and HFT preparation proved very useful… and we look forward to
confirm it with successful FLG tests.
SCS January 2018! LATEST DEVELOPMENTS
TAISHAN Unit 1 is expecting to have CFL authorisation in coming
days
French Flamanville 3 EPR plant just finish beginning of January
CFT successfully
Using also dedicated commissioning simulator loaded with latest
I&C database
Taken into account TAISHAN REX
SCS January 2018Thank you for your attention !
Questions ?
Romain BALP – FRAMATOME
Patrice ROTH - CORYS
Bian Xiu Shi 卞秀⽯石 - TNPJVC
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