SCS January 2018

SCS January 2018 Using a commissioning simulator to secure plant schedule

SCS January 2018

!  Agenda

TAISHAN EPR simulators Engineering Simulator overview V&V using Engineering Simulator Commissioning Tests on Simulator TSN U1 Cold Functional Tests TSN U1 pre Hot Functional BAS Tests

© Copyright TNPJVC

SCS January 2018

!  Taishan EPRTM Simulators •  CORYS provides simulators to both TNPJVC and FRAMATOME

Taiffu Simulator •  Copy of FA3 simulator for initial

operator training •  First version July 2010, updated

twice afterwards

•  Simulated I&C (spec level)

Full Scope Simulator •  RFT signed on Sept 27th 2014 •  Used full time for training •  Successful completion of RO

examination December 2014, SRO examination May 2015

•  Update forecasted after plant commissioning

•  Emulated operational I&C •  Simulated I&C in early stage

•  Emulated Safety I&C

TNPJVC Operators training and licensing

Engineering Simulator •  February 2015 1st version installed •  Four complete I&C update

afterward for CFT and HFT configuration

•  Simulated operational I&C •  Emulated Safety I&C

FRAMATOME Commissioning risk mitigation

•  FSS project early stage use of simulated I&C before switching to emulated I&C was fit to face upcoming commissioning challenges of TSN EPR

•  Design is still in progress, simulated I&C is more flexible than emulated I&C

SCS January 2018

!  Engineering Simulator Scope Normal Operation: Full range from primary circuit opened to 100% power �  Start-up, Shutdown, Load follow, House load, Reactor Trip… Incidental and accidental transients �  Steam Generator Tube Rupture �  Loss Of Coolant Accident �  Main Steam Line Break �  … Malfunctions & local actions �  failures of systems, �  equipment, �  breaks in pipes, �  loss of power, �  loss of I&C … Out of scope �  Operation from safety back-up panels �  Severe accident

TSN Engineering Simulator Simulation scope

•  NSSS •  BNI •  CI •  Turbine •  Electrical systems •  HVAC limited to reactor building

I&C •  Simulated operational I&C •  Emulated safety I&C •  Simulated HMI

SCS January 2018

HMI

Containment

Neutronic model COX3D

TXS: emulator T2000: ALICES simulation Turbine control: ALICES

Electrical distribution

Thermal exchanges, [B10], Water density

Heat losses, Breaks mass flow

and energy

Mass flow Pressure Enthalpy

exchanges

Manual orders Annunciation signalization

Orders and check backs

Power supply

Sensors measurements

Models Inherited from

Full Scope Simulator

RCS

Conventional Island Auxiliary systems

Rod controls

I&C

!  Engineering Simulator Model

OM690: ALICES simulation Thermal hydraulic: DRAC and SPL (ALICES)

SCS January 2018

!  Electrical and I&C simulation models

Electrical systems distribution fully simulated �  Main generator �  Emergency/Safety diesel generators �  Batteries

Non-safety class I&C: Simulated Siemens SPPA-T2000 �  PROS

Flexible for analysis/debugging, signals/parameters forcing, I&C logic modifications Highly detailed, down to the allocation to cabinets and fallback values Easy initial conditions maintenance

�  CONS cabinets are all synchronized, and I&C time transfers not in the model

Safety-class I&C: Emulated FRAMATOME TXS �  Functionality for on-line diagram and running code display,

parameters modification and implementation of hardware malfunctions

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SCS January 2018

!  Electrical and I&C simulation models

Black Boxes �  Simulated with CORYS engineering toolbox ALICES (turbine and

generator control, Emergency Diesel Generator, Chillers…)

HMI: Simulated OM690 �  Same look and feel as the real system

SCS January 2018

!  Engineering Simulator and V&V process

V-cycle �  ES can been loaded with I&C databases using export/import tools

within 2 months. So far 4 versions have been loaded for CFT and HFT

�  Latest design changes requested for site tests can be implemented quickly on ES to support design, V&V or commissioning ~45 design modifications tested on ES to prepare HFT

… before platform tests

after platform tests…

OR

Import I&C database and HMI

XML import

TEC4 I&C Diagrams Simulation Diagrams

SCS January 2018

!  Engineering Simulator and V&V process

V&V activities for an I&C plant configuration are done at different level Advantage of Engineering simulator versus other test means �  Fully integrated I&C (safety and operational I&C, priority management, main black boxes) with plant HMI

(operating displays, procedures and alarms) and process model (closed loop) �  Engineering simulator is the best test means that can provide FRAMATOME engineers with a

comprehensive feedback over the design and procedures quality �  Simulated operational I&C is flexible and easy to use to correct/adapt until configuration is frozen. Very

useful to support design and standard V&V.

Limitations �  Not a qualified tool – complementary of mandatory standard V&V and help to design �  I&C performance (time responses) not representative of the real system �  Are process models and simulated BBOX representative enough ? �  Advanced tool requiring specific skills to work efficiently

•  Functional verification by Design (Per System)

•  Implementation verification by I&C (Per System)

•  Test Bay platform (I&C in cabinets or emulator) (Per System)

•  Engineering Simulator (I&C and process model)

•  Site Commissioning

SCS January 2018

!  Engineering Simulator test objectives

The initial objective was commissioning risk mitigation by testing: �  Normal operation procedures �  Commissioning procedures, ~85 procedures chosen among:

Main plant Control loops NSSS Fluid systems tests Power supply loss (Main/Auxiliary grid transfer, Emergency Diesel Generator) I&C division loss

→ Complex systems, harsh transients, deviation from normal operating range…

Engineering Simulator use was extended to: �  Test of I&C transverse functions hardly testable on site �  Particular Operating Rules (operation with loss of an I&C function) �  Emergency Operating Procedures test �  Human factor tests �  Pretest and validation of I&C design changes before standard V&V �  Control loops preliminary tuning �  FRAMATOME Commissioning team training �  Site tests preparation (hydro test, BAS test…)

SCS January 2018

!  REX - Benefits for Commissioning

Validate complex/risky commissioning test procedures �  Test sequences, feasibility (I&C interlocks or spurious actions) and

ergonomics �  Check component protection features and assess risk of equipment

damage �  Identify the required I&C temporary modifications to be performed during

tests

Verify and validate I&C behavior together with the process �  Complex scenario involving many I&C systems interfaces �  Control loops behavior, Optimization strategy identification, and pre-tuning �  Study fallback operations (reverse path, loss of control loops, …)

Secure schedule �  Early findings of design/procedure flaws saves time on site

SCS January 2018

!  REX - Benefits for Commissioning Training �  Very efficient to train staff for good surveillance and avoiding human errors �  Commissioning team CFT training and S1 Training

Mandatory Commissioning and Operation training for Startup Shift Engineers

Team building and Communication between disciplines �  Design and commissioning engineers work out issues together �  All disciplines are involved at some point (Process and Safety team, I&C,

Commissioning…)

On site support for design/commissioning teams �  Design evolutions and Commissioning tests adaptation can be work out quickly �  Efficient tool for troubleshooting

SCS January 2018

!  TSN U1 Cold Functional Tests In November 2015, specific simulator activities were done by FRAMATOME to finalize CFT preparation using a CFT I&C version. The engineering simulator was used for different purposes : �  Validation/redlining of Normal operation procedures used for CFT

performance, �  Validation of TP ENS 21 hydro test procedure on the simulator, �  Identification of all the I&C temporary modifications necessary to avoid

spurious actions or blocking actions from I&C during CFT Performance, �  Validation/Tuning of some control loops used during CFT, �  Training/qualification of Shift Supervisor Engineer on the simulator before CFT

(one week).

SCS January 2018

!  TSN U1 Cold Functional Tests

Meanwhile TNPJVC rehearsed CFT as well on the FSS �  FSS I&C was unfortunately not in CFT configuration �  Validation of emergency plan for over pressure transients during CFT �  Elaboration of RBS start up and pressure control plan �  Working on the risk of safety injection from diversification signals �  Working on I&C interlocks

SCS January 2018

!  TSN U1 Cold Functional Tests TSN Unit 1 Cold Functional Test (CFT) successfully completed on Jan.27th, 2016 �  TNPJVC and FRAMATOME preparation proved to be complementary �  No major problem of procedure identified during CFT �  The temporary I&C modifications identified during preparation and on

simulator were exhaustive for hydro test (no concern during CFT Performance)

�  Good behavior of the control loops optimized on simulator during CFT performance.

SCS January 2018

!  TSN U1 preHFT BAS Tests

TSN Unit 1 preHFT NI Electrical Power Supply Change-over Tests (TP BAS) �  ANT/AST switchover �  Switch-over to EDG (LOOP situation) �  SBO Diesel Generator Black Start �  Complex I&C logics with fully integrated plant �  Many I&C forcing and scripting to conduct some tests �  Potential risk for some equipment 3 BAS tests run on Engineering Simulator by FRAMATOME BAS test coordinator �  Run 1 and 2

Detect main I&C design issues for simulated systems Debug simulator electrical model + BBOX issues (EDG/SBO/chillers/…) Improve TP tests strategies and instructions

›  In particular I&C forcing and scripts to be used during the tests (TCA)

�  Run 3 performed just before site tests Rehearse critical tests taking into account latest site constraint (RPV closed) Finalize and validate critical design change Validate TP and TCA and gain confidence for upcoming site tests

SCS January 2018

!  TSN U1 preHFT BAS Tests

Tests completed successfully on TSN U1 on March 3, 2017 �  No major issues found on the ES simulation scope, mostly synchronization

issues due to I&C performance that could not be seen with simulated I&C, and BBOX issues

�  Logic issues found on systems out of ES simulation scope (mostly HVAC) and/or tests not rehearsed on ES

Despite known limitations (HVAC/BBOX), ES preparation was highly valuable

SCS January 2018

!  Conclusion

Close partnership between CORYS and FRAMATOME engineering teams allowed regular update of the simulator to stick to the design and meet plant schedule Engineering simulator allows us to �  Discover and solve issues (I&C, procedures) before site tests �  Gather different teams and improve communication and cooperation �  Train our staff efficiently A powerful tool to support design integration and commissioning �  First full integration of I&C coupled with process before site tests �  Detail design I&C simulation is very relevant for Commissioning

Even though it is not as representative as an emulator (time responses in particular) A bug found in the simulator I&C logic or parameters is a bug on site as well… …and the flexibility of the simulation allows to quickly sort it out The exact I&C forcing to be done during Commissioning can be tested

�  Simulator most advanced users are now members of the Start Up Team ES is a well known and recognized tool now on the TSN project CFT and HFT preparation proved very useful… and we look forward to confirm it with successful FLG tests.

SCS January 2018

!  LATEST DEVELOPMENTS

TAISHAN Unit 1 is expecting to have CFL authorisation in coming days French Flamanville 3 EPR plant just finish beginning of January CFT successfully �  Using also dedicated commissioning simulator loaded with latest

I&C database �  Taken into account TAISHAN REX

SCS January 2018

Thank you for your attention !

Questions ?

Romain BALP – FRAMATOME Patrice ROTH - CORYS Bian Xiu Shi 卞秀⽯石 - TNPJVC