1. ENGINEERING SIMULATOR A-D TECHNOLOGY K. W. WONG November 2009

2. OUTLINE A.DIFFERENCES BETWEEN A FULL SCOPE SIMULATOR (FSS) AND AN ENGINEERING SIMULATOR (ES) B.DIFFERENT KINDS OF SIMULATORS C.DESCRIPTION OF ENGINEERING SIMULATORS (ESs) D.APPLICATION OF TOTAL ES E.PLATFORM FOR DIGITAL I&C DEVELOPMENT AND TESTING F.DIFFERENT USUAGES OF ES G.ADVANTAGES OF USING ES TO COMPLEMENT FSS ENGINEERING SIMULATOR

3. DIFFERENCES BETWEEN A FSS AND AN ES A FSS is a “plant-referenced simulator”. It is to be used for training and certification of operator and senior operator. It is to be used for the administration of the operating test and to meet experience requirements for applicants for operator and senior operator licenses. In the United States, FSS is regulated in accordance with 10CFR 55.46 “Simulation facilities”. Regulatory Guide 1.149 “Nuclear Power Simulation Facilities for Use in Operator Training and License Examinations” describes methods acceptable to US NRC. Regulatory Guide 1.149 endorses ANSI/ANS-3.5-1998 “Nuclear Power Plant Simulators for Use in Operator Training and Examination”. Therefore, in the U.S a FSS must comply with requirements specified in ANSI/ANS-3.5-1998. An ES is not to be used for operating test and not to be used to meet experience requirements, therefore, there is no requirement for compliance with ANSI/ANS-3.5-1998.

4. DIFFERENT KINDS OF SIMULATORS - 1 A. Plant Referenced Full Scope Simulators B. Part Task Simulators C. Basic Principle Simulators D. Compact Simulators E. Graphical Simulators F. Plant Analyzer

5. DIFFERENT KINDS OF SIMULATORS - 2 A. Plant Referenced Full Scope Simulators – for training and certification of nuclear power plant operators and senior operators. B. Part Task Simulators – for training on a specific part of plant operations or for training for special phenomena, e.g. for training of steam generator tube ruptures. Specific plant system(s) or phenomena may be simulated in detail. C. Basic Principle Simulators – for illustration of general concepts, demonstration of fundamental physical processes of the nuclear power plant. The simulation scope focuses on the main systems and auxiliary or support systems may be neglected.

6. DIFFERENT KINDS OF SIMULATORS - 3 D. Compact Simulators – for training on operating procedures in a simplified form, for basic training of new operators, and personnel not working in the control room. The scope of simulation is typically limited and the full control room hard panel can be replaced by soft panel. E. Graphical Simulators – for representation of control parameters and operating environment. For example, control room panels may be displayed as hard panels or soft panels. F. Plant Analyzer – for studying of complicated plant transients and accidents in details. The full control room is not replicate. Data for complex analysis of plant operating behavior is typically represented in a format conducive to analysis.

7. ENGINEERING SIMULATOR - 1 Total ES Detailed core and NSS systems process modeling, e.g. RELAP5/NNKM TRACS/NEMO Complete and exact NSS/BOP logic and process modeling Complete and exact HSI modeling Use soft panel to represent control room hard panel B, C, D, E, F

8. ENGINEERING SIMULATOR - 2 A specific application of the total ES to develop into a DCIS test platform for the Taipower Lungmen ABWR Project is now described. An ideal test environment for digital I&C validation will be to connect the digital I&C system(s) to be tested to a nuclear power reactor and operate the nuclear power reactor in different scenarios to generate different sets of test signals to test the digital I&C system(s). However, this will not happen. In the past Use test fixtures and test tools to generate limited amount of test signals Use simple simulators to generate limited and approximate test signals

9. ENGINEERING SIMULATOR - 3 In Lungmen ABWR Project, a total ES is used as the basis to provide the test environment to perform close loop validation for digital I&C systems.

10. ENGINEERING SIMULATOR - 4 Application of Total ES (Lungmen DCIS Test Platform) Core Modeling (TRACS/NEMO) Thermal hydraulics 3-D Vessel 1-D Components Neutronics 3-D core modeling (209 assembly nodes X 14 axial nodes) 209 fuel assemblies map to 7 thermal-hydraulic channels NSS & BOP Systems Modeling Detailed modeling of 105 plant systems Detailed process modeling Detailed logic modeling – one to one exact replica of plant control logic diagram Detailed electrical modeling – one to one exact replica of electrical diagram Control Room HSI Modeling Complete and exact HSI using display translation tool Soft panel to represent control room hard panel

11. ENGINEERING SIMULATOR - 5 Ref.: C. C. Chen, et al., Engineering V&V for DCIS Lungmen Nuclear Power Plant, NPIC&HMIT 2009, Knoxville, Tennessee, April 5-9, 2009

12. ENGINEERING SIMULATOR - 6 Major control systems - non-safety systems Invensys – IPS I/A Most of non-safety systems MHI Hitachi Rod Control Information System GEIS – Mark-VI/VIe Systems related to turbine control Feedwater Control System Recirculation Flow Control System Steam Bypass and Pressure Control System Automatic Power Regulation System Major control systems - safety systems GE NUMAC Neutron Monitoring System Reactor Protection System Leak Detection and Isolation System DRS Plus 32 Engineered Safety Feature Systems

13. ENGINEERING SIMULATOR - 7 Total ES System Description Invensys Application Workstation, AW70 Invensys FSIM Plus resided in a PC Invensys Redundant Field Device System Integrator Module, FBM233 Invensys Redundant Fieldbus Communications Module, FCM100Et Invensys Control Processor, CP270 Total ES Server PC to document test results Network system Invensys FSIM Plus is integrated with Total ES Server This allows as built digital control system software to be validated in a fully simulated plant environment.

14. ENGINEERING SIMULATOR - 8 CONCEPTUAL VIEW

15. ENGINEERING SIMULATOR - 9 Physical View

16. ENGINEERING SIMULATOR - 10 Software Description Invensys FSIM Plus Contains as built logics for the systems to be validated Total ES Detailed reactor core modeling Detailed process modeling for 105 plant systems Detailed logic modeling for 105 plant systems Control Room Human System Interface Communication software between Total ES and FSIM MODBUS protocol

17. ENGINEERING SIMULATOR - 11 Communication description A MODBUS driver is available as part of Invensys FBM233 system. Software based on the MODBUS protocol is developed and installed in the ES server to enable communication between FSIM Plus and ES.

18. ENGINEERING SIMULATOR - 12 Data transfer between Total ES and FSIM Before Test (Verification of P28 control logic) P28 logic model within Total ES sent valve position command to P28 process model within Total ES P28 process model within Total ES perform process calculation and return valve position input and pressure input back to P28 logic model within Total ES During Test (Verification of P28 control logic) P28 logic model within Total ES is disabled. P28 process model within Total ES is directed to communicate with FSIM via MODBUS interface

19. ENGINEERING SIMULATOR - 13 The Total ES is used to perform dynamic, integrated, interactive and close-loop testing of DCIS non-safety related systems. Dynamic testing means performing testing of the digital systems under different operational scenarios (normal, abnormal and transient) of the nuclear power plant. Integrated testing means performing testing of the digital systems as an integral part of the total plant rather than as isolated individual systems. Interactive testing means performing testing of the digital systems including human system interactions. Close-loop testing means that there will be feedback from the plant to the system to be tested.

20. ENGINEERING SIMULATOR - 14 Validation of 10 BOP systems has been completed (Ref.: Chia- Kuang Lee, et al., Digital System Validation Testing in the Lungmen Project, NPIC&HMIT 2009, Knoxville, Tennessee, April 5-9, 2009)10 BOP systems Additional validation of 24 BOP systems is in progress and expected to be completed by June 2010.24 BOP systems Three kinds of validations are performed Validation of human system interface Validation of logics and alarms Validation of System Operation Procedures (SOP) Automating tools have been developed to facilitate validation.

21. ENGINEERING SIMULATOR - 15 Engineering simulator capabilities used include Software panel to enable operator action Insertion of initial conditions (IC) Setting up of remote functions (RF) to simulate local operator actions Using malfunctions and variable overwrite to trigger different equipment conditions

22. ENGINEERING SIMULATOR - 16 Test results of the 10 BOP systems include HSI deviations Logic/alarm deviations DCIS implementation deviations Data base deviations SOP deviations Test results are documented and submitted for follow up action

23. ENGINEERING SIMULATOR - 17 Currently in progress Set up Test Platform to validate Triple Modular Redundant (TMR) Systems 1 GE MARK VI Suitcase Trainer to validate Steam Bypass and Pressure Control System (C85) 1 GE MARK VIe Suitcase Trainer to validate Feedwater Control System (C31) Recirculation Flow Control System (C81) Automatic Power Regulation System (C82) Interfaces between Total ES and GE MARK VI/VIe

24. ENGINEERING SIMULATOR - 18 In progress

25. PLATFORM FOR DIGITAL I&C DEVELOPMENT/ TESTING The TOTAL ES will act as a “Virtual Plant” providing plant data to drive individual Plant Digital I&C system or integrated Plant Digital I&C system. Interface with Plant Digital I&C system HARD I/O INTERFACE that will provide I/O signals to drive the Digital I&C Hard I/O system. NETWORK INTERFACE that will provide datalink soft I/O to drive the Digital I&C system.

26. CRITERIA FOR DIGITAL I&C PLATFORM Criteria for the Digital I&C Test Platform The core modeling should be based on advanced best estimate core modeling codes. The process and logic modeling should be the same as the actual plant. A V&V process should be implemented to assure that the implementation of the plant process and logic modeling is correct. A configuration management process should be in place to assure that updates and modifications of the digital I&C platform are tracked. Testing should be formal, structured and documented. Processes and tools should be in place to document, record and present test results and the performance of testing.

27. MULTIPLE USUAGES OF ES - 1 Development and testing for Digital I&C Dynamic and interactive design and validation of plant control systems One system at a time Several systems/group of systems at a time Integrated system Dynamic verification of plant procedures Normal, abnormal and emergency procedures Test procedures (Pre-operation Test, Startup Test)

28. MULTIPLE USUAGES OF ES - 2 Plant analysis Conceptual studies Transient and accident analysis Design analysis and optimization Establishing process parameters and equipment sizing Efficiency improvement studies Root cause analysis of observed phenomena Failure mode and effects analysis

29. MULTIPLE USUAGES OF ES - 3 Design, Design change and plant modification analysis and verification Human Factor Engineering (HFE) design, analysis and V&V Training and Education Operation training Engineering training System/component training Modeling training Fundamental concept training

30. MULTIPLE USUAGES OF ES - 4 Research and Development Software V&V methodology study – role of advanced simulators Common failure, diversity, defense in depth study using advanced simulators PRA and risk assessment study using advanced simulators