FSRUG Meeting San Antonio, Texas February 21, 2011 Design and Operations Considerations of a Distributed Control System Mike Phillips Title slide [from Title Slide master] The title slide is available as a Title Master and the background and graphic elements are fixed. Text is editable for the slide heading and presentation details but the small compliance text exists in editable form only on the Title Master itself. This type area should be used only for the purposes of compliance text and should not be replaced by other content. Font, type size and colours are fixed for the Title Master style and should not be modified. Footer details Footer detail appear in the bottom-left corner of the slide and appear in fixed positions and order. Editing of the Footer details is done by accessing ‘Header and Footer’ under the ‘View’ menu in PowerPoint®. © Invensys 00/00/00 Invensys proprietary & confidential

FSRUG Meeting – San Antonio Invensys Attendees Mike Phillips – Director Nuclear Marketing Chris Wiegand – Nuclear Client Executive Scott Zimmerman – Customer Sales Executive Tim Frost – Project Engineer Masud Ahmad – Product Sales Engineer Daren Zahabizadeh – Technical Sales Consultant Tony Moreland – NA TSC Director Participating in the Vendors Nights Monday & Tuesday. Look forward to seeing your there.

Distributed Control Systems Discussion Topics What is a distributed control system Why go digital in the first place What is the difference between a DCS and a PLC What are the pros and cons of each Implementation of Digital Systems Lessons Learned Project Documents / Specifications SQA and your system Cyber Security Service and Maintenance of your system Customer Feedwater Solution Overview and Results Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins.

Distributed Control Systems Why go digital in the first place? Obsolescence Single Point Failure Vulnerability Maintenance Issues Problems maintaining old system Spares Original suppliers out of business Nuisance Plant Trips / Startup delays Tribal Knowledge / Plant “As Builts” Multiple platforms and vintage Workforce attrition $$ $$ Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins. $$

Distributed Control Systems Plant Computer & Data Acquisition Potential Upgrade Applications

Distributed Control Systems Wikipedia: A distributed control system (DCS) refers to a control system…..in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring. DCS is a very broad term used…….to monitor and control distributed equipment. Plant Computer & Data Acquisition Potential Upgrade Applications

Distributed Control Systems Distributed Control Backbone Plant Computer & Data Acquisition Distributed Control Backbone Potential Upgrade Applications

Distributed Control Systems - PLC A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes. The PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. PLCs may include logic for single-variable feedback analog control loop, a "proportional, integral, derivative" or "PID controller". Historically PLCs were usually configured with only a few analog control loops. Where processes required hundreds or thousands of loops, a distributed control system (DCS) would instead be used. As PLCs have become more powerful, the boundary between DCS and PLC applications has become less distinct. Plant Computer & Data Acquisition PLC Potential Upgrade Applications HMI

Distributed Control Systems DCS & PLCs: What are the pros and cons of each? DCS PROs DCS gives you a plant backbone and the built in capacity to distribute controllers and expand the system in the future. Single platform for the plant... learn and maintain ONE platform, the only difference in the “distributed controllers” is the application configuration Higher level built in configuration tools. Wider range of control algorithms On-line repair and self calibration (may decrease surveillances) DCS CONs Non-DCS HMI solutions can provide more flexibility in developing application specific graphics Longer Outage time and Higher cost of installation Non-safety rated and no triple redundancy offering Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins.

Distributed Control Systems (PLC’s) DCS & PLCs: What are the pros and cons of each? PLC PROs Allows an “islands of automation” approach to plant upgrades Triple Modular Redundancy (TMR) for “Production Critical” applications On-line repair and self calibration (may decrease surveillances) PLC Speed response times Ladder Logic, Function Block, and Structured Text programming languages Single, Dual, & Triplicated options PLC CONs Limited set of predefined Algorithms (but can be developed) Need to build communications infrastructure Utilizes Non-DCS packages for HMI graphics Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins.

Distributed Control Systems So, do I use a DCS or a PLC? But first, what is the reason for considering a digital upgrade and what is the overall objective? Are you considering a plant wide digital solution? Do you have a digital upgrade plan in place for your facility? Solving a nagging maintenance issue with no future digital plans? Capturing operational knowledge? Looking for a common platform for BOP systems Is there a specific SQA Level required? Maybe we should look at lessons learned…….. Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins.

Digital Systems - Lessons Learned Specifications Educate your team on what is possible Define the functionality you will require in your system At a minimum - develop a good I/O list to include in the specification. Result? More accurate proposals from the vendors Will get the project off on the right foot Clearly identify vendor documentation requirements Avoid the “Kitchen Sink” approach when listing Codes and Standards Increases the risk factor to the vendor & increases cost Penalized by Purchasing Determine the level of SQA that will be required. Make sure you understand your requirements so you can explain it to the vendor Example: Applying typical 1E requirements to a non 1E class system Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins.

Implementation of Digital Systems Specifications Give yourself time to write a good specification Make sure the schedule is realistic Un-realistic schedules increase pricing…..somewhere along the line Don’t forget about the Simulator Upgrade Should have a strong focus since it is usually the first to be implemented Are there plant standard devices? Encourage vendor to incorporate but be flexible to vendor options Network Switches Field Transmitters Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins.

Picking a Supplier Experience, Experience, Experience All Experience, not just Nuclear “Production Critical” projects especially Vetted Project Procedures and SQA Plan Experience with a variety of Nuclear Plant Digital I&C Projects Does the supplier have a strong history of product support and a strong migration path Past performance is an indication of the future performance Be wary of installing “one off” or obsolete equipment! Know what you are getting and get involved

Picking a Control System Platform Experience, Experience, Experience Will the platform lend itself to previous plant digital upgrades? Open or closed type of architecture Does it fit into the Plant Standardization philosophy? Is the Platform Fault Tolerant? Is the system a COTS Technology and used in other industries Knowledge of processes Data base of reliability data Economies of scale Longer term support from vendor Ask the question how will we maintain the system ourselves? Implement a configuration control program Allows ease of upgrading digital hardware and software Don’t drive yourselves into DIGITAL OBSOLESCENCE!

Enhancements Elimination of Single Point Failures Ease of Maintenance Reduction of test frequency of control system Automation of testing Additional Information available to operations and maintenance through the Human Machine Interface Improved diagnostics of the control system as well as process Management of Change Friendly

Project Issues Team for success Assign the proper personnel for the project and make sure they have the right attitude toward the project Design System Engineering Operations Simulator Maintenance IT Keep the same project team for the duration of the project Make sure management sees the project as top priority Need contractor help for the project? Have the contractor take on day to day plant responsibilities Let plant personnel concentrate on the project THIS IS YOUR FUTURE!

Project Issues Answer the question “Who will own the system?” If budget allows, include a training system If schedule will allow, get the system onsite early and try to “break it” The vendor you have chosen needs to be flexible to small additions that come up during the project Resist scope creep unless you take schedule and cost impacts into account. Train Early If possible go to training as part of the Control System evaluation Train key project personnel early in the project so they have better input during the project

Mechanical & Instrumentation Single Point Vulnerabilities To the extent possible, consider duplicating or triplicating critical system components. These include: Oil Pumps and Drivers Pressure Switches Supply Filters Header Pressure Transmitters Level Transmitters Servo Coils LVDT’s Coolers

Quad-redundant Hydraulic Trip Block Online Testing Online Repair No single point of failure Manifold mounting for easy installation and repair Fully instrumented for automatic testing IPS Confidential

Mechanical & Instrumentation 3D Modeling of new assemblies Hydraulic Control Components Panel Hydraulic and Pump Skids IPS Confidential

Human Machine Interface Issues Resist the urge to hold onto the past. Try to eliminate hard panels whenever possible If possible, convince operations to not try to duplicate the hard panels on the HMI Information overload Resist the urge to alarm everything. This can end up overwhelming the operator. Again use the simulator to work out Human Factor issues. Decide where the HMI will be mounted. Is there spare space? Can it be mounted where the hard controls were located? Do you need to get more creative on where and how to mount the monitors?

Good or Bad?

Cyber Security Issues Minimize connections between the control network and corporate networks and only then through firewalls and buffers Do not connect the control network to the internet If possible limit communications to a unidirectional output to the plant computer and plant historian

Summary Communications between all parties essential Be open to what has been done in and outside nuclear Understand the details of all requirements Don’t make assumptions Study lessons learned and truly implement them in your project Start small and grow with those successes with open systems Too much at once – is a recipe for failure Cultural change – the most challenging of them all! Take ownership its your Future

ABWR Advanced Control Room

OK, But Where’s the Beef? Digital Control Systems are as good as the planning, expertise of the people, platform reliability, application capability, SQA, and installation and start-up of the system. Today’s systems are not just replacements……they are Digital Upgrades Offering: Operational philosophy enhancements improved startup and runtime performance Significant reduction of unplanned unit trip outages  These advanced control techniques allow: Less operator required interaction Automatic control, especially during start-up and shut-down when most unit trips are caused The entire control system is more capable of handling normal operation as well as process upset conditions

Feedwater Upgrade Enhancements Redundant Sensor Algorithms (RSA) Dual Transmitter Input Algorithm Dual Transmitter Input Algorithm with Arbiter (Voter) Triple Transmitter Input Algorithm Redundant Valve Outputs Fully Integrated Single Element/Three Element Control Philosophy Control Element Assembly Position Indication Logic Incore Flux Monitoring Calorimetric Monitoring Sequence of Events Recording Atmospheric Steam Dump Control Steam Bypass to Condenser Control

Typical Client Need Replace an aging existing Feedwater Control System and Improve Operational Reliability and Availability Design a digital replacement solution for this critical system Should address & mitigate future obsolescence Should incorporate both high reliability and high availability as inherent attributes Should allow the plant operator to focus on the plant behavior Focus the operators attention on monitoring field parameters critical to running the plant effectively Allow quick response on performing corrective actions Integrate the new feedwater control system with the main turbine controller and the feedwater turbine controller Remove single point vulnerabilities in the system wherever possible

Critical Feedwater Considerations Important To Safety Opportunity Section 7.7 of the SRP, NUREG-0800, indicates increased scrutiny of certain non-1E systems by the NRC Reason? Failure of these systems would challenge the plant safety systems Feedwater Control is certainly one such application Feedwater is critical to continuous plant operation When the feedwater system goes down, the plant goes down A single component failure causing unscheduled plant outages Cost of downtime averages $1M / day Challenge: Provide highly reliable and available digital solution Improve the operational efficiency of the plant – gain Megawatts! Decrease downtime and regulatory risk

The Existing System The unit has two steam turbine driven feedwater pumps Both pumps are required to function to achieve 100% power Significant operation risk and concern for any pump loss Additional Operational Procedures to compensate for risk In case of a sudden pump loss it is not possible for the Operator to react quickly enough to prevent a turbine trip. Recovery from Reactor Trip = 3 days at a total cost of operation of $5.5M

The Feedwater Control Solution Digital Upgrade was funded for feedwater control including: Main Feedwater Control Valves Feedwater Bypass valves FWP Demand Signal Automate By-Pass valves operation and integrate operation into start up and shut down sequence Control from the control room. Automate control valve surveillance testing Push button test from the control room Test time dropped from 2 days to 15 minutes per valve Integrate control functionality Seamless communication with the previously upgraded main turbine controller for start up, shutdown, and runback control. Automatic demand placed on feed water turbine governors.

The Feedwater Control Solution Provide Improved Operator Awareness Dual redundant Operator HMI screens for control and monitoring. Separate large display mounted to provide easily visible chart recorder screen. Existing chart recorders were removed. Integrated system now automatically responds to any feed water level change On Unit Runback the system can now survive 50% reduction in Reactor Power without Operator Intervention No Operator action required No Plant Trip

Solution Value One mitigated outage Recovered Original Investment Reduced maintenance costs Developed a consultative relationship with the upgrade team Client is a valued reference and proud of the results Master Services Agreement now in place Future Committed Business Identified Positively impacting relationships across the industry The ultimate “Win - Win” scenario Increased Safety Margin, Reduces Operating Cost No Regulatory Oversight $2.2M Savings minimum for each mitigated event

FEEDWATER – Menu Select Screen

Steam Generator 1 & 2 Feed & Steam Flow

FEEDWATER – Valve Control & Chart Recorders

FEEDWATER – Pump Control

Summary: DCS or PLC? Definitions gave us a feel for the differences but very little definition of where to use one over the other. One seems better for a system with a lot of analog loops and the other seems better for electro-mechanical high speed applications. One seems better overall if long range digital upgrades have been scheduled and the other seems more suited to “islands of automation” or stand alone systems But tie all the islands of automation together and what do you have? A distributed control system. So after all that, the real answer is……it just depends Use the right platform for the application and utilize “lessons learned” “Production Critical” / “Important to Safety”– TMR PLC’s Balance of plant – DCS and tie it all together

Operational Benefit Before the Feedwater Controls there were many operational challenges.  The controls were poorly tuned and trips were not uncommon during power up and power down operations-intensive procedures.   “Having split-range 3-Element control on the bypass feed water valve as well as the main valve allowed for automated controls to handle the switchover from the bypass to the main valve.  This reduced operator direct manual interaction, and thereby reduced trip incidents.  We also rotate our Steam Generator Feedwater Pumps.  The split range 3-element controls remove the perturbations associated with switching out those pumps.”  A reduction in trips and down time was a direct results of the improved tuning and controls. There was a plant transient soon after the controls were installed in which the Hotwell Makeup Valve failed to open.  The operators by that time overcame their instinct to place the feed water system in manual and instead let the controls take action.  The feed water DCS response was called “outstanding”.   It would have been a much more stressful event for operations using the pre-DCS controls. The DCS provided much more system and process information.  They are able to use this type of data to ascertain process characteristics (valve and pump non-linearities).  The system then had the tools to compensate for these characteristics and provide a better response to control actions.

Operational Benefits Another customer attributes smoother operations and the reduction of single points-of-failure to installation of the DCS and Feedwater controls.  “We were able to eliminate over 40 single points-of-failure per unit using the DCS Feedwater controls.  It also simplified the startup of our second Feedwater pump.  When starting the second pump, speed balancing used to be an operator-intensive manual procedure.  The DCS block features allow for the controls to completely balance the pumps in automatic.  Our swap over from startup valve to main valve was greatly simplified.  It used to be an operator manual swap that took about an hour to perform.  It is now an automatic event that occurs on they fly with no specific interaction required.  “I have seen a valve transfer occur as they were tying a turbine online (and in single element) with no significant level perturbations in the steam generators”  The controls were improved to have one set of tuning parameters, and one set of inputs.  “If you have narrow range level, steam flow, and Feedwater flow, that’s all you need to run single element or three element at any power level.”

Please come by our booth for additional information and discussion Thank you for your attention! Please come by our booth for additional information and discussion Questions?

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