getting another 20 yeard from your simulator...

Getting Another 20 Years from Your Simulator Hardware

15 January 2018

Barnard GagnonTung Nguyen

2018 Power Plant Simulation Conference (PowerPlantSim’18)

Topics

• L3 MAPPS Brief Overview

• Introduction

– Hardware and software obsolescence

– Upgrade challenges/objectives

• Panel Instruments and I/O System

• A/V System

• Computer Systems

• Power Supply/Protection

• Conclusions

PPS 2018 © 2018 L3 MAPPS. All rights reserved. 2

L3 MAPPSBrief Overview

About Us

L3 TechnologiesHQ: New York City38,000 employeesUS$10.5 billion (2016)4 Business Segments

© 2017 L3 MAPPS. All rights reserved. 4

Aerospace Systems

38%

Electronic Systems

28%

Comm. Systems

20%

Sensor Systems

14%

Global NPP SimulationFootprint

(celebrating 45 yearsof innovation)

L3 MAPPSHQ: Montreal

3 Markets: Naval, Power Gen., Space

Control Systems & Simulation

Solutions Overview

1/17/2018 © 2017 L3 MAPPS. All rights reserved. 5

5

Full Scope Simulators Severe Accident Simulation Simulator Modifications Classroom Simulators Part-task Trainers

Engineering Simulators Learning Modules

L3 MAPPS Power Systems and Simulation

SIMULATIONCANDU Plant Computers

CONTROLSSystem Knowledge Modules Learning Simulators

Introduction

Introduction

• Most US NPP simulators were originally built in 1970-80’s

– Simulator (Control Room and Auxiliary) panels, instruments, I/O system and models

– Upgrades generally performed incrementally based on budget considerations and most urgent needs

– Simulator maintainers face many challenges over time, particularly obsolescence

• What could go wrong?

• Is it easy to repair/replace?

• Other challenges?


Introduction

• Hardware obsolescence over time

– Failures more frequent

– Instrument repairs become difficult

– Sometimes plant “borrows” simulator’s spare parts

– Replacement parts are difficult to find

OEM no longer in business

Supply/support from OEM no longer available

Other sources can be difficult to find (e.g. eBay)

$$$

– Computers/computer parts obsolescence

– Interface cards no longer available (e.g. PCI vs. PCIe)


Introduction

• Software obsolescence issues

– Operating Systems (O/S) not supported on newer computers/servers

e.g. Windows XP cannot run on new DELL computer

Hardware drivers not available

– Third-party software doesn’t run on newer O/S

Compilers (e.g. Compaq Fortran, Microsoft Visual Studio, etc.)

Centralized database (e.g. Microsoft SQL Server)

– Third-party software licenses no longer available from OEMs

– Antivirus not updated on older platform cyber security concerns


Simulator Maintenance and UpgradesChallenges/Objectives

• During simulator operation/training

– Minimize down time due to simulator failures (hardware and software)

– Improve recovery time

– Quick equipment/computer replacements

– Minimize and reduce simulator maintenance cost, including spare parts

– Simplify deployment of new simulator software

• During simulator upgrades (minor or major)

– Minimize simulator outage time

– Optimize testing and validation time

– Minimize cost

• Ultimate goal

– High simulator availability and reliability!


Panel Instrumentsand I/O System

Panel Instruments and I/O System Upgrade Approaches

• Several strategies

– I/O System replacement

Incremental upgrade to free-up legacy I/O components for spare parts

Full I/O system replacement

– Re-wiring

Spaghetti?

Documentation existence and accuracy

Brittle wires

– Instruments replacement

Availability?

Re-engineer

Spare parts managementPPS 2018 © 2018 L3 MAPPS. All rights reserved. 12

L3 MAPPS’ Approach for I/O Systems: Compact I/O

• Many distributors worldwide• Large user base: industrial, building automation, marine, etc. • Wide variety of I/O modules• High density modules• Low power consumption• Passive ventilation• I/O controller has the capability of running user-programmable

control logic (i.e. synchroscopes)• Advanced diagnostics• Orchid® Input Output to manage I/O communication

I/O System MCR Panels

• Quick replacement of failed modules

• Minimize down time

• Minimal or no re-wiring

• Inexpensive modules

– No need to repair


Compact I/O System Advantages

• Provides very clean setup and wiring

• Requires very little space

• Flexible

• Expandable

• Easy to maintain

• Negligible noise production

• Compact I/O solutions have been deployed by L3 MAPPS on

– Full Scope Simulator projects

– Simulator Upgrade projects• High reliability

– Mean Time Between Failures (MTBF) from 20 to 40 years


Instrument wiring retained as-is, maximize use of ribbon cables

Minimized simulator downtime during changeover Junction modules are passive

Krško (Slovenia) Simulator – I/O System Replacement

Legacy

Junction Modules

New Design

I/O System

Simulation Server


Diablo Canyon (USA) Simulator - I/O System Replacement

Instrument wiring retained as-is (minimized re-wiring errors) Minimized simulator downtime during changeover Adapters are passive

RTP I/O Adapter Cards(DO, DI, AO, AI)

BEFO

RE

Edge

Con

nect

or

Device Hood

Connector

AFTE

R

Edge

Con

nect

or

Device Hood

Connector

I/O Module

I/O ModuleI/O Module

LegacyNew Design


Re-Engineered Panel Instruments

• If feasible, source original instrumentation

• Obsolescence and cost are key drivers for re-engineering

– Retain the same look-and-feel

• Spare parts

– Request spare parts early


Incandescent Lamps

• Incandescent lamps tend to fail on a regular basis and are expensive over time

• Replace with LEDs

– Match the physical fidelity (color and intensity)

– Reduce failure rates significantly

Reduce frequency of DORT testing

– Less power consumption

Reduce the sizing of the power supplies


Annunciators

• FSS using LCD screens for annunciators windows

• Training needs assessment to be performed when physical fidelity and human factors deviations exist between the reference unit and the simulator

Tihange 1 (Belgium) Simulator


Dual-Unit Simulator Control Room Panels

• Reactor 1 desk fully instrumented

• Reactor 2 desk using hybrid solution

– Instruments for controls

– LCD screens for monitoring instruments and displays

Heysham 1 (UK) Simulator


Other Considerations

• Use of instrument connectors

– Quick removal, repair and installation

– Increased initial installation cost

– Reduce downtime due to re-termination of instruments

• Spare parts strategy

• Identification of single points of failure


A/V System

A/V System

• Orchid® Multimedia Manager

– Runs on Windows computers

• Recording of audio and video feeds individually

– Debriefing (i.e. playback) synchronized with the simulation or standalone

• Use of Commercial Off-The-Shelf equipment

– IP Cameras and microphones

– Digital encoders for DCS screens

– Can connect to existing cameras(digital or analog)

– Interface to audio mixer using virtual sound card

• Reduces need for special hardware (e.g. joystick)

– Camera controls through user interface


Computer Systems

Virtual Machine

• Two servers connected to a common disk array (RAID configuration)

• Each server capable of simultaneously running a virtualized Full Scope Simulation and a backup/development machine

– DCS, PPC and more…

• Rapid switchover with no loss of data

• Countermeasure for hardware and operating system obsolescence

– Virtual machines can be installed on newer platforms with minimal effort and cost

• Used for upgrades while keeping the previous simulation server ready in case of problems


Computer Systems - Other Considerations

• RAID controllers (software or hardware)

– Avoid loss of precious data

• Performing incremental upgrades

– Simulation environment and tools

– Third-party software (compilers, SQL database, O/S, etc.)

• Mid- and long-term upgrade strategy

– Plan/allocate budget in advance

– Be proactive

• Offsite backups

• Availability of ready-to-go/pre-tested devices and computers


Power Supply/Protection

Power Supply/Protection

• Use of Uninterruptable Power Supply (UPS) and Power Conditioner

– Main focus on computers/servers and I/O system

– Avoid power transients on sensitive electronic equipment

– UPS allows graceful shutdown of computers and avoid potential data corruption

– Configure automatic notifications of power failures (e.g. email, SMS, etc.)

– UPS and Power Conditioner solutions can be combined


Conclusions

Conclusions

• We looked at

– Panel Instruments and I/O System

– A/V System

– Computer Systems

– Power Supply/Protection

• Important to be forward-looking and plan for potential failures

• As much as possible, use equipment with large user community (i.e. not only in the nuclear business)

• Maximize the use of COTS components

– However, re-engineered instruments might be necessary

• Virtualization makes simulator more hardware independent

• Provision wisely for spare parts

– Obsolescence / repair / minimize simulator downtime

• Availability of ready-to-go/pre-tested devices and computersPPS 2018 © 2018 L3 MAPPS. All rights reserved. 30

Thank YouL3 MAPPS

8565 Côte-de-LiesseMontréal, Québec, Canada

H4T 1G5

Tel: +1 (514) 787-4999 Fax: +1 (514) 788-1442

Web: www.L3T.com/MAPPSLinkedIn: L3 MAPPS

L3 MAPPS8565 Côte-de-Liesse

Montréal, Québec, CanadaH4T 1G5

Tel: +1 (514) 787-4999 Fax: +1 (514) 788-1442

Web: www.L3T.com/MAPPSLinkedIn: L3 MAPPS

2018 Power Plant Simulation Conference (PowerPlantSim’18)

getting another 20 yeard from your simulator...

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