Modern HMI Concepts And Engineering / Documentation Tools For Nuclear Power Plants

Peter Papajewski IAEA Technical Meeting Chatou, France September 2005

Contents

 Single Window To The Process  Sophisticated Power Plant Engineering and Online Documentation Tool
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Single Window To The Process

 Actual Situation
Analogue, hard wired I & C technologies Rudimentary proprietary digital control systems Hybrid control rooms Existing systems are obsolete and expensive to maintain Limited expandability

Single Window To The Process

 Advanced Control Room Approach:

One type of VDU for the whole plant Full access to all plant data and controllers Based on an open system architecture, total integration of specific, diverse subsystems More effective training process oriented Interoperability between HSI, DCS and specific subsystems Plant life-time support philosophy
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Single Window To The Process

 Basics
COTS (Commercial Off The Shelf) Product Truely open system architecture  3rd party subsystems easy to interface and integrate HSI/DCS based on Hardware, Software & Communication Standards  Solaris and/or MS-Windows XP OS  Sun Workstations and/or Standard PCs  Ethernet 100 MBit / 1 GBit MESH network
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Historian Server/Client

Personal ComputerW95/98,2000,NT,XP X-Terminal Terminal Server Client Web-Server Office-Client Data analyser

Internet / Intranet Client Server/ Computer Unix / VMS etc.

Internet /Intrane t

Office Network

2nd Ethernet - TCP/IP, Novell, DECnet, NFS, SNA, X.25, OSI

optional

Mobile Workstation

Workstation

Applikation Workstation Workstation (redundant) Systembus / MESH Ethernet 100 MBit/1Gbit Fibre Control Processor (redundant)

Applikation-Workstation Server

AlarmsOnline

Triconex TMR FS-PLC (TV AK6 / NRC SER) (redundant)

Alarm Printer

High Speed Ethernet Fieldbus (100MBit) Fibre FBM200

Alarm Management

Remote I/O Fieldbus Moduls (redundant) Profibus DP/PA FoxComm HART

PLC Modbus (redundant) Foundation Fieldbus

Migration

Remote I/O

PLC

Intelligent Transmitter

Single Window To The Process

 Advantages & Benefits

Easy integration of existing subsystems by a wide set of standard interfaces (library of more than 100 different interfaces available) Single point of plant information Whole DCS application suite available for all subsystems  reporting, alarming, historical data archiving,  Unique and plantwide data validation  Monitoring of safety and safety-related subsystems  One common database distributed over the system Plant Focused Operator Training Plant lifetime support strategy
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Single Window To The Process

 Reference
Lungmen project - GE ABWR 30 diverse subsystems are integrated by standard interfaces into one HMI System  Reactor Protection  Other Safety Systems  Neutron Flux Monitoring System  Turbine Protection and Turbine Controller  Many other systems

Single Window To The Process

Lungmen Advanced Control Room

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Engineering / Documentation Tool For Plant Life Cycle Information Management

Sophisticated Power Plant Engineering and Online Documentation Tool for Life Cycle Asset Information Management

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Engineering / Documentation Tool For Plant Life Cycle Management

LCAIM (n. abbr.) Life Cycle Asset Information Management

Ensuring that the documents and plant information of all physical assets professional managed during the life cycle of the capital facilities, from the Front End Engineering Design to the de-commissioning.

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Structured Data The Information Format needed for Life Cycle Asset Information Management

Increasing sophistication of Information Forms and cost of conversion from hard copy

Structured Data Native File Electronic Image Hard Copy

Filing & Retrieval Tracking & Monitoring

ISO 15926 XML As Built 3D TIFF PDF

Word Excel AutoCAD

Structured Data Model

Life Cycle Asset Information Management

Workflow for Creation

Content Management

Increasing sophistication in Information Management and business benefit

Requirement: Consistent structured plant data

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Engineering / Documentation Tool For Plant Life Cycle Management

Comos

Information driven Quality and quantity of engineering information

Contr. Sys.

XML

Intelligent standards EPC Document driven

DXF / DWG

ePLAN

Data erosion
DXF / DWG

Handover

sales

from EPC to O&M

Data erosion

EPC 2-4 years

commisioning 6 month

Operation and maintenance 25-40 years

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Life Cycle ManagementWhere you are ?

Simulation PFD Ressourcenmanagement Process Data Sheets

Functions Plans

Circuit Diagrams ?? 3D Floorplans

Electric Docum.

Loops

P & ID

Hook-Ups

2D Floorplans 3D Piping

Maintenance

Piping CLasses

Techn. Data Sheets

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Engineering / Documentation Tool for Plant Life Cycle Management

Reality:
EPC and Owner Information and Knowledge Management Approach is still document driven The EPC documents and drawings handed over from the EPC to Owner and O&M does not reflect the actual plant. More then 60% of the information in data sheets, drawings and other documents are inaccurate or incomplete or not consistent! O&M Engineers spend more then 50% of their time looking for documentation and information a very costly misuse of resources!

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Engineering / Documentation Tool For Plant Life Cycle Management

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Engineering / Documentation Tool For Plant Life Cycle Management

Process Graphics Overlays

Unified object oriented Database

Historian Alarming

Object Database

VGB 170C Function Plan

P & IDs

Field Cabinets Hook-Ups

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Engineering / Documentation Tool For Plant Life Cycle Management

Concurrent Engineering

Basic Engineering

Detail Engineering

 Improved Accuracy  Improved Productivity  Reduced Engineering Costs  Simplified Maintenance

DCS System Configuration

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Comos PT - I/A Series Concept

P&ID

KKSEngineering Unit-Structure

New Solenoid-Valve D_NAA30AA02

Device Installation
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Comos PT - I/A Series Concept

FUPFUP-VGB LoopLoop-Plan

P&ID

Engineering

Field Connections

Control New Solenoid Valve Engineering New Solenoid Valve

Device Installation

D_NAA30AA02

D_NAA30AA02

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Comos PT - I/A Series Concept

FUPFUP-VGB LoopLoop-Plan

P&ID

Process Engineering

I/AI/A-I/O Cabinet

Device connections

DCS CabinetLayout

Control Engineering
Device Installation
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Comos PT - I/A Series Concept

FUPFUP-VGB LoopLoop-Plan

P&ID

I/A FoxCAE TAG- List TAG-

Process Engineering I/A-I/OI/A-I/O-Cabinet

Device connections

DCS Cabinet Layout

Control Engineering Device Installation

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Comos PT - I/A Series Concept

Import

Export

Comos PT
TAGList

Toolkit

Back-Navigation/ Dynamic Processdata

FoxCAE
CP Database

I/A System

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Comos PT - I/A Series Concept

TAG-List Project (Comos PT) Generate Database with FoxCAE ToolKIT Library

Process Display from AW/WP FoxDraw

Download in CP

Faceplates from AW/WP ToolKit

Objects are known in the whole System

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Valve module

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Valve module

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COMOS PT - I/A Series Interface

click FUP

Get the related FUP detail

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Dynamic

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Engineering / Documentation Tool For Plant Life Cycle Management

Quality, Quantity of Plant Asset Information Business Benefit

LCAIM world class EPC

LCAIM world class O/O

Option 1 LCAIM Requirements Before signing EPC Contract

Plant Information for O/O without LCAIM Approach

Option 2 LCAIM Start during EPC Option 3 LCAIM Start after Handover during O&M P C Commission

Plant Information for EPC without LCAIM Approach

O&M

Tender E

Operation & Maintenance Refurbishment

LCAIM Requirements defined before signing the EPC Contract

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COMOS PT Virtual Project Room

Viewing & Web-Navigation (Virtual Project Room) Web-enabled document checking-in Integration Navigation

3rd Party Interfaces

Engineering Functionalities

Data Import Export (Excel)

3rd Party Application Integration

Integrated Document Management System and Project Quality Control

Centralized COMOS Database

COMOS PT Integration Platform for the EPC and O/O a real Virtual Project Room for global Project Execution
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I/A Series Interface - Benefits

 Data consistency  Data transparency (process eng.,meas. & control strategy, PCS)  Complete electronic documentation (basic-eng.,detaileng.,startup, commissioning and maintenance)  Complete plant and site documentation  Open and flexible interfaces (API, VisualBasic, etc.)  Concurrent engineering concept  Multi-user capability  Customer specific documentation  reduced engineering time  Graphical configuration  Re-useable engineering (prototyping, typicals, ToolKit)  Complete documentation is available on every DCS WS  User can manoeuvre within the complete documentation
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Historian Server/Client

Personal ComputerW95/98,2000,NT,XP X-Terminal Terminal Server Client Web-Server Office-Client Data analyser

Internet / Intranet Client Server/ Computer Unix / VMS etc.

Internet /Intrane t

Office Network

2nd Ethernet - TCP/IP, Novell, DECnet, NFS, SNA, X.25, OSI

optional

Mobile Workstation Applikation-Workstation Server Workstation Applikation Workstation Workstation (redundant) Systembus / MESH Ethernet 100 MBit/1Gbit Fibre Control Processor (redundant) Triconex TMR FS-PLC (TV AK6 / NRC SER) (redundant) COMOS Server

AlarmsOnline

Alarm Printer

High Speed Ethernet Fieldbus (100MBit) Fibre FBM200

Alarm Management

Remote I/O Fieldbus Moduls (redundant) Profibus DP/PA FoxComm HART

PLC Modbus (redundant) Foundation Fieldbus

Migration

Remote I/O

PLC

Intelligent Transmitter

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Questions ? ? Thank You For Your Attention

Contact: Peter Papajewski Invensys Systems GmbH, Duesseldorf, Germany phone.: Mobile: +49 211 5966 343 +49 163 5966 343

e-Mail: peter.papajewski@ips.invensys.com

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