1. FSRUG Meeting San Antonio, Texas February 21, 2011
Design and Operations Considerations of a Distributed Control System
Mike Phillips
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Invensys proprietary & confidential

2. 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.

3. 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
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4. 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 $$ $$
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5. Distributed Control Systems
Plant Computer & Data Acquisition
Potential Upgrade Applications

6. 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

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

8. 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

9. 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
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10. 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
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11. 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……..
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12. 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
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13. 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
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14. 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

15. 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!

16. 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

17. 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!

18. 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

19. 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

20. 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

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

22. 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?

23. Good or Bad?

24. 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

25. 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

26. ABWR Advanced Control Room

27. 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

28. 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

29. 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

30. 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

31. 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

32. 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.

33. 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

34. 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

35. FEEDWATER – Menu Select Screen

36. Steam Generator 1 & 2 Feed & Steam Flow

37. FEEDWATER – Valve Control & Chart Recorders

38. FEEDWATER – Pump Control

39. 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

40. 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.

41. 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.”

42. 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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