New Build Simulators - L-3 MAPPS - L
Transcription
New Build Simulators - L-3 MAPPS - L
A semi-annual report on L-3 MAPPS Power Systems and Simulation activities CPR1000 New Build Simulators Issue 33 | July 2011 deployed at Hongyanhe Site Page 6 IN THIS ISSUE VIEW POINT....................................................................2 Milt Caplan talks about Fukushima COMPANY NEWS...........................................................3 Michael Reed joins L-3 M&PS NEW BUSINESS.............................................................4 Embalse DCC refurbishment Callaway AEPS models SPECIAL REPORT...........................................................6 Hongyanhe Simulators in service Ling Ao Phase II Simulator PAC CUSTOMER PROFILE....................................................8 Eletrobras Eletronuclear’s Ilson Soares PROJECT HIGHLIGHTS............................................... 10 PROJECT PERSPECTIVE............................................. 12 Greg Zakaib discusses teamwork TECHNICAL DEVELOPMENTS.................................... 14 Orchid® Touch Interface INFO EXCHANGE......................................................... 16 2011 Owners Circle™ Conference (Tampa) Recent Events Upcoming Events LIGHTER SIDE............................................................. 19 viewpoint Fukushima Why are we hanging our heads so low? On 11 March 2011, Japan was hit by 9.0 earthquake and subsequent tsunami. The Fukushima Dai-ichi nuclear complex suffered major damage and is not expected to reopen. The earthquake and tsunami disabled the reactor cooling systems, leading to nuclear radiation leaks and triggering local evacuation. There has been much press coverage on this topic – some useful and based on science, some plain non-factual nonsense. Being a key simulation technology supplier for nuclear plants all over the world and a provider of plant computer system hardware for CANDU plants, L-3 MAPPS is of course always monitoring the media and seeking lessons learned from the events that unfolded at Fukushima Dai-ichi. For this issue of simnews, we invited Milt Caplan of MZConsulting Inc. to share his views with us. It has now been about four months since the horrific earthquake and tsunami that caused the damage at the Fukushima Dai-ichi Nuclear Power Plant. The people of Japan continue to suffer from this mindboggling natural disaster with the death toll at well over 20,000. And yet when we hear about Japan on the news it is the accident at the nuclear power plant that dominates the headlines. state and some radiation continues to be released, although progress is being made. Now let’s look at the consequences of this disaster. First and foremost, there have been no fatalities due to radiation; there has been no exposure to the public that exceeded allowable limits, while six workers have received doses higher than their already increased The world has reacted. Countries like Germany are moving to abandon allowable limits. And while the evacuation zone is still in place and nuclear power in the disaster’s wake, Switzerland has followed and will be for some time, at this point it seems likely that there will be Italy has stopped its movement away from a moratorium. In most no long-term contamination requiring moving people away from their other countries there is continued support for nuclear power, although home permanently. there is a definite pause in new build as the lessons are learned and That being said, I think we should all take a moment and be proud of safety is re-evaluated. our industry, proud that in the worst accident in 25 years, there are Within the nuclear industry there are many who are crushed by this no immediate and no expected longer-term radiation fatalities. And event; in fact no one is more disappointed and concerned about that is what nuclear safety is all about. Fukushima than the industry itself. We have this tremendous ability So when we say we can we do better, what do we mean? We can’t for self-criticism. We believe we need to suffer because of this, and have less than zero fatalities or less than zero excessive exposures. we know for certain that we need to do better. The IAEA is looking into Going back to the requirements, I would say the two real issues how to improve safety at nuclear plants, and I have seen numerous needing improvement are the fact that there were releases, likely write-ups suggesting a number of preliminary lessons learned. Some due to cracking in the containment structures – and this should not include placing backup generators at a higher level; others are happen; and of most importance, the time to get the fuel cooling looking at having a strategic power supply available for delivery to systems functioning and removing all of the decay site within a short time frame after an accident as heat is excessive. The fear caused to the public needed. Many of these ideas are quite good, and and the subsequent reaction of governments may I expect that the best of these will ultimately be be the largest lasting impact. We need to set more implemented. In fact there has already been an strict guidelines for how to do better here and focus IAEA sponsored ministerial conference on nuclear on reducing the time to cold shutdown following safety held as a direct result of this event. such extreme events. I am sure we can think of As engineers, we have a tendency to jump to many other improvements in terms of reduced solutions before we have the problem well defined. consequences, and that should be a matter for Almost every day, I hear people within the industry further discussion before talking about fixes. It is and elsewhere stating that “we need to improve interesting to see the IAEA revising their charting safety.” However, what I do not see is anyone system for this event to focus on three items: risk clearly articulating what we mean by that. Let’s of criticality, long-term decay heat removal and discuss and identify the requirements of such a mitigation of radioactive releases. statement. Defining “improved safety” is the first Now while it is also useful to look at the many critical step. Many of the suggestions so far will potential improvements to the plant designs to help with the next earthquake and tsunami, but reduce the likelihood of such an accident, it would what about other unexpected events? be imprudent to assume that some other event So let’s go back to the beginning. We had an extreme natural disaster that we haven’t contemplated would never happen. Hence one of that was well beyond what was expected for this plant. At first the the biggest lessons learned is that low-probability events can indeed plant performed as designed, but the tsunami was too much and happen. And this means we need to review and see how to potentially many things went wrong. The natural disaster affected multiple units make improvements in severe accident management. at the site and strained the ability of the workers to meet the needs But overall, I am hoping that at some point this event will be seen to of the plant to the extreme. Backup power was lost for weeks, not an have had a number of positives. I can’t think of any other industry assumption in the analysis. I’m sure that there will be many, many where the worst event in decades is one that results in no deaths. other things that went wrong once the accident is studied in detail. This is because this is what we expect of ourselves. Other energy And most of all, the plants are yet to be placed in a safe cold shutdown 2 | simnews | Issue 33 Summary of severe (≥ 5 fatalities) accidents that occurred in fossil, hydro and nuclear energy chains in the period 1969-2000 OECD Energy chain Non-OECD Accidents Fatalities Fatalities/ GWey Accidents 75 2,259 0.157 Fatalities Fatalities/ GWey 18,017 0.597 819 11,334 6.169 Coal (without China) 102 4,831 0.597 Coal Oil 165 3,713 0.132 232 16,505 0.897 Natural Gas 90 1,043 0.085 45 1,000 0.111 LPG 59 1,905 1.957 46 2,016 14.896 Hydro 1 14 0.003 10 29,924 10.285 Nuclear 0 0 --- 1 31* 0.048 So as I see it there are two outcomes from an event such as this one. First, as we would all expect, we will have many lessons learned so that we can make improvements in nuclear plant operation and safety. And that is great as we all strive for continuous improvement in safety in this industry. viewpoint 1,044 Coal (data for China 19941999) and a long-lasting impact on the people of Northern Japan. But of equal or even more importance, perhaps this event will also demonstrate that even Total 390 8,934 1,480 72,324 in what are perceived as very *Note: These are immediate fatalities only. bad nuclear accidents, the Source: Comparing Nuclear Accident Risks with those of other Sources – NEA 2010 consequences have a minimal effect on population health. If industries don’t ever think this way. Accidents resulting in deaths are we explain things correctly, we can demonstrate that even when these commonplace and readily accepted. accidents happen (and I hope we have also learned that accidents do This can be clearly seen in the above chart. Or as stated by Stewart indeed happen), we can have confidence in their outcomes, and thus Brand in his book Whole Earth Discipline, “Radiation from nuclear build confidence in the public that global catastrophe is not around energy has killed not a single American, but of all these energy by- the corner as a result of nuclear power and that indeed the industry products, it is the only one we dread.” Or look at the German example. is what we want it to be – SAFE. An accident in Japan that is of no direct consequence to Germany (no tsunamis on the Rhine!) has resulted in a dramatic decision to stop its nuclear power program. Yet disease coming from an organic farm Milt Caplan, President of MZConsulting Inc., has 30 years’ has killed many in Europe and there is no call to eliminate organic experience in the nuclear industry advising utilities, governments farming or call international ministerial conferences on organic food and companies on new build nuclear projects and investments in safety. This is just the world that we live in. uranium. He is the current chair of the World Nuclear Association So why are we all hanging our heads so low feeling that we have Economics Working Group and is on the faculty of the World failed? A 40-year-old plant has survived a once-in-a-lifetime natural Nuclear University where he teaches nuclear economics and disaster. The consequences to the public have been modest, mostly nuclear plant structuring and financing. Milt obtained his inconvenience and fear, but no injuries or deaths, while the natural Bachelor of Engineering in Nuclear Engineering from Rensselaer disaster that caused it has resulted in tens of thousands of deaths Polytechnic Institute in Troy, New York, USA, and an MBA from the University of Toronto. L-3 MAPPS now part of Controls & Integrated Systems Sector Mike’s office will be in L-3’s Poway, CA facility. Reporting to Mike will be Don Roussinos, president of L-3 Maritime Systems, Peter Dawson, president of L-3 MAPPS and Tony Gardiner, vice president and general manager of L-3 Dynamic Positioning & Control Systems. L-3 Westwood, New Orleans will continue to report to Jerry Ozovek, president of the Power Systems Sector until further notice. Prior to joining L-3, Mike was with General Atomics serving as senior vice president, Survivability Group. Prior positions included president & CEO of their Electronics Systems Company and senior vice president for the Advanced Technologies Group. Prior to joining General Atomics in 1997, he completed 22 years of naval service as an engineering duty officer having achieved the rank of Captain. His active duty assignments included sea duty on USS Saratoga, tours at the Naval Sea Systems Command, the Board of Inspection and Survey and Supervisor of Shipbuilding in Bath, ME and Pascagoula, MS. He was director of design for the Navy’s DDG51 Class Aegis Destroyer Program and Navy Program Manager for their Advanced Electric Technology Program Office. Significant programs under his development at General Atomics include Electromagnetic Aircraft Launch System (EMALS) and Advanced Arresting Gear (AAG) for the CVN78 FORD Class aircraft carrier. He holds both an Ocean Engineer advanced degree and a Master’s degree in Naval Architecture and Marine Engineering from the Massachusetts Institute of Technology and a Bachelor’s degree in Electrical Engineering from Iowa State University. July 2011 | simnews | 3 companynews At the end of June 2011, L-3 Marine & Power Systems (M&PS) Group was reorganized into functional areas or sectors. The Group president, Robert Leskow, announced the formation of the Controls & Integrated Systems Sector. This new sector within M&PS is comprised of L-3 Maritime Systems (Leesburg, VA and Newburyport, MA), L-3 MAPPS (Canada, UK and India), L-3 Westwood (New Orleans, LA) and L-3 Dynamic Positioning & Control Systems (Poway, CA). The Controls & Integrated Systems Sector will align these Michael R. Reed, business entities to leverage President, Controls & Integrated Systems Sector core competencies, maximize efficiencies and improve products and services to better support our customers and provide opportunities for revenue growth. Michael R. Reed has been appointed to the role of president of the Controls & Integrated Systems Sector, reporting directly to Robert Leskow. newbusiness L-3 MAPPS to Add Value to Embalse Refurbishment with Digital Control Computer Systems L-3 MAPPS has been awarded a contract from Nucleoeléctrica Argentina S.A. (NA-SA) to replace the Embalse nuclear power plant’s Digital Control Computer (DCC) systems hardware. Four DCC systems will be delivered to NA-SA under the contract. The first system will be used as a testing and training platform and is due to be installed in early 2013. Three other redundant DCC systems for plant operations are expected to enter service in mid2014. The project design process is currently underway. DCC systems are used to monitor and control the major reactor and power plant functions at CANDU* nuclear power plants. The new DCC systems will feature the latest SSCI-890 CPUs and modern VMEbased replacements for the existing Ramtek display system, and will replace the Varian 73 computer systems and related equipment. “L-3 MAPPS is committed to working with NA-SA on the Embalse plant,” said Michael Chatlani, vice president of marketing & sales for L-3 MAPPS Power Systems and Simulation. “Along with the full-scope simulator we are currently developing, the replacement DCC systems will help improve plant operations.” “In support of the Embalse plant refurbishment project, NA-SA is pleased to work with knowledgeable industry partners like L-3 MAPPS,” said Rubén Semmoloni, Embalse nuclear power plant lifeextension project director, NA-SA. 4 | simnews | Issue 33 The Embalse nuclear power station is one of two operational nuclear power plants in Argentina. It is located on the southern shore of a reservoir on the Rio Tercero, near the city of Embalse in Córdoba Province, 110 kilometers southwest of Córdoba City. The single unit at Embalse is a CANDU pressurized heavy water reactor with a net output of 600 MWe, which went into commercial operation on January 20, 1984. Embalse also produces the cobalt-60 radioisotope, which is used for medical and industrial applications. With the current plant refurbishment plans, the station’s life is expected to be extended for another 25 years. * CANDU is an acronym for CANada Deuterium Uranium and is a registered trademark of Atomic Energy of Canada Ltd. The CANDU system is a design that uses deuterium oxide (heavy water) as the moderator and coolant, and natural uranium as fuel. newbusiness Alternate Emergency Power System work at Callaway L-3 MAPPS has earned follow-on orders from Ameren Missouri to upgrade the full scope simulator for the Callaway Energy Center in Callaway County, Missouri, USA. One order will provide for the addition of an alternate emergency power system (AEPS) model, and in the other order L-3 MAPPS will modify the interface between its Orchid® Core Builder and the fuel analysis code used to perform the actual nuclear power plant fuel cycle updates. The AEPS model upgrade is scheduled to be completed in four months, and the fuel data input model will be updated in the fourth quarter of 2011. The interface between Orchid Core Builder and the data generated by the fuel analysis code will also be updated as the Callaway Energy Center transitions from CASMO4/SIMULATE3 to Westinghouse’s PHOENIX-P/ANC. “Since our first order for upgrading the Callaway simulator in 1997, the simulator has been progressively upgraded by L-3 MAPPS to the point where the legacy simulator has in effect been replaced and is entirely functioning in L-3 MAPPS’ industry-leading Orchid environment,” said Michael Chatlani, vice president of marketing & sales for L-3 MAPPS Power Systems and Simulation. “Thanks to the The AEPS added to the station includes four 2-megawatt diesel performance gained with L-3 MAPPS models, the robust simulation generators located 1.5 miles off-site to improve Callaway’s ability technology and our committed service, we continue to secure addto mitigate a station blackout. The AEPS generators provide an ons and we greatly value Ameren Missouri’s business.” alternate source of power during a station blackout that is different from the emergency diesel generators and off-site resources. The Ameren Missouri has been providing electric and gas service for more off-site diesel back-up systems start up when there is a loss of than a century, serving 1.2 million electric and 126,000 natural gas both safety-related emergency diesel generators and a loss of off- customers in central and eastern Missouri. The company’s service site power. As an enhancement to the simulator, L-3 MAPPS will area covers 63 counties and 500 towns, including the greater St. model the AEPS generators associated switchgear, transformers Louis area. Since 1984, the Callaway plant has been providing safe, and connection to the Central Electric Power Cooperative, all with clean and affordable electricity. The electricity generated by the L-3 MAPPS’ Orchid Modeling Environment. Invensys’ Wonderware Callaway plant is enough to meet the needs of 780,000 average InTouch human-system interface for the AEPS will be emulated with households every year. L-3 MAPPS’ Orchid Control System. Callaway Unit 1 Quick Facts Utility: AmerenUE Reactor Supplier: Westinghouse Reactor Type: PWR Capacity: 1,190 MWe (net) Date of Operation: December 1984 Location: Fulton, Missouri, USA July 2011 | simnews | 5 specialreport L-3 MAPPS Deploys Simulators for the CPR1000 New Build Hongyanhe Site A second pair of L-3 MAPPS-developed simulators for the CPR1000 nuclear plant design have entered service at the Hongyanhe Nuclear Power Training Center. The first simulator, which was developed for units 3 and 4, was handed over to Liaoning Hongyanhe Nuclear Power Co. (LHNP) in November 2010, and the second, for units 1 and 2, in March 2011. After extensive testing, the simulators were deployed to allow operator training to proceed. Several updates to the simulators are still to follow as updated digital control system (DCS) information is made available to L-3 MAPPS. The simulators support all major training requirements and are available for LHNP to prepare operators well before first fuel loading of Hongyanhe unit 1, which is targeted for early 2012. The simulators have been tested for normal operations – from cold shutdown to 100 percent full power and from 100 percent full power to hot, intermediate and cold shutdown, as well as for mid-loop operations and core performance. In addition, numerous transient tests have been successfully demonstrated, including loss of coolant accidents, steam line breaks, loss of feedwater, reactor and turbine trips, load rejections, steam generator tube ruptures, and more. The deployment of the Hongyanhe Phase I simulators follows the delivery of a series of high-performance, reliable simulators provided by L-3 MAPPS and its partners for China Guangdong Nuclear Power Company’s (CGNPC) Daya Bay, Ling Ao and Ling Ao Phase II sites. The first three full-scope simulators are being used for operator training six shifts per day with an availability of 99.8 percent (of uptime). The simulation technology has also been used for other applications, including technical support for the operating plants and emergency planning, among others. The Hongyanhe project is the first to be built in northeast China as part of the country’s plans to upgrade its aging industrial base and will be operated by LHNP. The new Hongyanhe Nuclear Power Plant site, located in Hongyanhe Town of Wafangdian, 104 km north of Dalian City in Liaoning Province, will have six generating units, each featuring China’s standard CPR1000 design, and a 1,080-megawatt three-loop Pressurized Water Reactor (PWR) whose design is being coordinated by China Nuclear Power Engineering Company. The Hongyanhe plant units are the first in a series of CPR1000 units that utilize Mitsubishi Electric’s MELTAC safety digital control “The successfully launched Hongyanhe simulators are the latest system (DCS) and the CTEC-supplied HOLLiAS non-safety DCS. The examples of L-3’s progressive simulation technology and techniques,” Hongyanhe plant serves as a reference for other plants already under said Michael Chatlani, vice president of marketing & sales for L-3 construction, namely the Ningde, Yangjiang and Fangchenggang MAPPS Power Systems and Simulation. “We stand ready to support Nuclear Power Stations. the continued growth and success of the Chinese nuclear power industry with our state-of-the-art simulation solutions for operational Liaoning Hongyanhe Nuclear Power Company is a joint venture excellence and safety.” between China Guangdong Nuclear Power Co. (CGNPC), China Power Investment Corporation (CPIC) and Dalian Construction Investment The Hongyanhe simulators take advantage of process models Group. CGNPC is responsible for project construction and the developed and maintained within L-3 MAPPS’ Orchid® simulation first five years of commercial operation of the plant with full-scale environment. The plant’s non-safety control sequences, developed participation by CPIC. by China Techenergy Co. (CTEC), have been translated by L-3 MAPPS and are also available in Orchid for quick modification, visualization and validation of the control design by LHNP. 6 | simnews | Issue 33 Milestone on Ling Ao Phase II Simulator Project witnessed in January 2010 by China’s nuclear regulatory authority, the National Nuclear Safety Administration. Unit 1 of the Ling Ao Phase II complex entered commercial operation in September 2010 and Unit 2 is planned for August 2011. To achieve PAC, the simulator was updated to account for all plant changes since the August 2009 simulator delivery, including commercial operation results. A simulator availability test was performed, which demonstrated a simulator availability of 99.42 percent. With this milestone achieved, the simulator’s warranty period is now underway. “With the plant and digital control systems (DCS) designs being firmed up in parallel with the simulator’s development, the supplier and customer teams faced tremendous hurdles to complete this project,” said Peter Dawson, president of L-3 MAPPS. “We are extremely proud of what the team has accomplished on the Ling Ao Phase II program and are grateful to so many contributors, including representatives from DNMC, CNPEC, AREVA and Siemens for their outstanding collaboration.” Seated from left to right: Doris Kittelmann (Siemens), Jean-Paul Mauduit (AREVA) and Zhang Ruiqiong (CNPEC). Standing from left to right: Ma Deyou (DNMC), Frederic Personeni (AREVA), Li Jinguang (DNMC) and Gregory Zakaib (L-3 MAPPS). The Ling Ao Phase II nuclear power plant full scope simulator (FSS), the first-ever simulator for a CPR1000 plant, has attained another significant milestone. In a ceremony held in Paris on 28 June 2011 marking the issuance of the provisional acceptance certificate (PAC), L-3 MAPPS joined AREVA, Siemens, Daya Bay Nuclear Power Operations and Management Company (DNMC) and China Nuclear Power Engineering Company (CNPEC) to formally hand over the simulator to DNMC on behalf of the Ling Dong Nuclear Power Company. In cooperation with AREVA and Siemens, L-3 MAPPS successfully delivered and installed the FSS in August 2009. The first plant license operator examinations were successfully carried out on the FSS and Integrated with AREVA- and Siemens-supplied DCSs, replica control room panels, and a stimulated human-machine interface, the FSS features L-3 MAPPS’ advanced instructor station capabilities and a proven Windows-based graphical simulation environment. Advanced plant models have been deployed and validated for the reactor, thermal-hydraulic, balance of plant, electrical, and I&C for the turbine control and other miscellaneous systems not controlled by the AREVA/ Siemens DCSs. The safety systems DCS is AREVA’s Teleperm XS, and the operational I&C DCS system is Siemens’ SPPA-T2000 with OM690 human-machine interface. The Ling Ao Phase II nuclear plant, owned by Ling Dong Nuclear Power Company, comprises the first two CPR1000 generating units put into service. The CPR1000 is a Chinese standard design featuring a 1,080-megawatt three-loop pressurized water reactor, whose design is coordinated by CNPEC. Both the plant and the simulator are located in Da Peng on the coast of Daya Bay in Guangdong Province, about 45 km from the city centre of Shenzhen and about 50 km from Tsim Sha Tsui, Hong Kong Special Administrative Region. July 2011 | simnews | 7 specialreport L-3 MAPPS Attains Major customerprofile Navigating Simulator Challenges with Eletrobras Eletronuclear’s Ilson Soares In the summer of 2009, L-3 MAPPS commenced work on upgrading the Angra 2 full scope simulator (FSS) at the Almirante Álvaro Alberto Nuclear Power Station for Brazil’s Eletrobras Eletronuclear (ELETRONUCLEAR). Angra 2 is a Siemens-designed pressurized water reactor (PWR) with a net output of 1,350 MW that was connected to the grid in 2000. It is located near the town of Angra dos Reis, roughly 200 km west of Rio de Janeiro. To get some additional insight and provide a snapshot of the progress made on the simulator upgrade project, simnews speaks with Mr. Ilson Soares, ELETRONUCLEAR’s Head of Training/Simulators. simnews: The original Angra 2 simulator has an interesting history. installation, tests, effective use for training and disassembling of the The simulator was delivered by the original vendor —Thomson-CSF— equipment, took place between October 1982 and February 1985. in 1982, but Angra unit 2 went into service in 2000. Please explain. In March 1985 the simulator was transported to Brazil and installed at I. Soares: Right after the Brazilian Government’s decision to start the ELETRONUCLEAR Training Center. It has performed an extensive the construction of the Angra 2 nuclear power plant (NPP), training program for operators, technical managers, commissioning ELETRONUCLEAR negotiated two separate contracts for the and licensing personnel from foreign nuclear power plants, as well acquisition of its simulator: one with the reference plant as specialists for national and foreign organizations involved with manufacturer (Siemens/KWU), for the supply of the simulator control several activities related to nuclear installations and also with the room hardware, development and supply of the plant specifications, operation of conventional electric power plants. training and qualification of performance of commissioning tests of Through this program, the Advanced Training Center “CTAS” has the simulator; and another one with a simulator manufacturer, for been offering theoretical and practical training for personnel from the supply of the remaining simulator hardware (computer system, various organizations and NPPs in Germany, Spain, Switzerland, USA interface, instructor system), integration of all hardware components and Brazil since it began operations in September 1985. and development of the simulation software. simnews: Up until recently, the Angra 2 simulator was running on an The simulator was built by Thomson-CSF (France) and Siemens/ ENCORE RSX-6841D computer system. What were the main drivers KWU (Germany) between May 1978 and September 1982, at the for ELETRONUCLEAR to proceed with the current simulator upgrade Thomson-CSF facilities in Cergy-Pontoise, France. project? Due to the interruption of the Angra 2 NPP construction in the early I. Soares: Actually, the original computer system was composed 1980s, and, consequently, the postponement of the operator training of three GOULD/SEL 32/75 computers, one GOULD/SEL 32/77 for the plant, ELETRONUCLEAR decided to make an agreement with computer and associated peripherals. These four computers ran in Siemens/KWU, aiming to temporarily use the simulator in Germany. a quadric-processor parallel system, with a shared memory system The Simulator was then installed in Karlstein, Germany, and some for common data interchange. This hardware configuration was later of the revenue obtained through the training of the personnel of changed to two GOULD/SEL 32/75 and two GOULD/SEL 32/77 German NPPs was transferred to ELETRONUCLEAR by Siemens/KWU. machines, and subsequently, to three GOULD/ SEL 32/77 and one The operation of the simulator in Germany, including the periods of GOULD/SEL 32/75 configuration. 8 | simnews | Issue 33 customerprofile Due to increasing hardware maintenance problems, mainly caused by the lack of replacement parts for those computers in Brazil, and the need for more computational power and larger main memory, ELETRONUCLEAR decided to acquire a new computer system. In early 1993, an ENCORE RSX-6841D computer system was acquired from ENCORE Computer Corporation and adopted as the simulator server in July 1993. This computer system was selected on the basis of software/hardware compatibility with the previous system, in order to significantly reduce the overall migration time. The choice proved to be the right one, and the new system was successfully put in operation in early 1995. Unfortunately, ENCORE computers were discontinued that same year. I. Soares: The Angra 2 simulator is quite old and all the major problems are related with this—its age. Many solutions that were used in the past, during its construction, are not available anymore. I would say that our main challenges were the conversion of the assembler codes to C language and the development of a new I/O controller, to connect the new computer environment to the simulator control room. For the second phase, the main challenge is to perform the conversion from bit to byte, which requires a change in the overall model structure. simnews: ELETRONUCLEAR personnel from the simulator organization and from the training department spent considerable time at L-3 MAPPS’ Montreal facility exercising the upgraded simulator in recent months. What was their impression of working with L-3 MAPPS personnel? What about their views on our fine city? During all those years, we have been keeping this simulator working with our internal software and hardware teams. In order to avoid hardware maintenance problems, we recently decided to rehost this I. Soares: The L-3 MAPPS personnel made a very good impression on simulator once again, converting all its assembler codes and making us. We were very well treated by everyone in the company, not only the all models portable and replacing the instructor station and three specific L-3 MAPPS team assigned to our project. The project team main simulated systems. managers follow the project development very closely; they try to solve problems as soon as they arise. During the factory acceptance simnews: Please describe the upgrade project for our readers. tests we were very impressed by the commitment, good relationship I. Soares: The first phase of the project was for L-3 MAPPS to rehost and teamwork of the whole L-3 MAPPS team, in particular, by the the simulator’s software to PC/Windows-based computers running very hard work done by the factory team leader. L-3 MAPPS’ modern Orchid® simulation environment with advanced instructor station capabilities. The legacy models programmed in To complement the great working experience, Montreal is a very assembly language were to be converted to C language. The aging nice city. It is relatively quiet, safe and very clean. The people on the master I/O controller was also targeted for replacement with a new streets are also very kind. master controller from L-3 MAPPS to establish I/O communications simnews: What’s left to do to complete the second phase of the with the hard panels. Angra 2 simulator upgrade project? In the second phase, the primary system models will be replaced I. Soares: In order to complete the second phase, we must complete with higher fidelity models. L-3 MAPPS will supply its advanced the development and integration of new modules for the reactor neutronics model generated by Orchid Core Builder to replace the core, the reactor coolant system, the containment and ventilation reactor core model and use Orchid Modeling Environment to provide systems. the nuclear steam supply system, containment and HVAC models. Several legacy modules and input/output routines must be updated simnews: What is the current status of the project? to transform bit-wise variables to byte-wise variables. Modules that I. Soares: The factory acceptance testing period for phase I was must be converted from bit to byte include several I&C modules, completed successfully on 13 May 2011. The Phase I equipment was alarms, electrical breakers, sub-loop controllers, plant computer then shipped to the Angra 2 site, installed, and verified in the middle signals and the input/output system modules. of June 2011. The current in-field activities include the installation, Of course, we will have another round of acceptance tests at L-3 testing and final integration of the replacement I/O controller. This will MAPPS’ factory in Montreal and then on-site acceptances tests then end with “whole simulator” (including the legacy I/O system with where the upgraded models will be tested for the first time with the the replacement I/O controller) site acceptance by ELETRONUCLEAR full simulator control room. and on-the-job training of the system. In addition, other in-field activities include change request (CRs) clearance and acceptance simnews: L-3 MAPPS is proud to be involved with the modernization of remaining Phase I CRs. At the same time, Phase II activities are of the Angra 2 simulator. Please provide any concluding remarks. proceeding. The development of the models that were upgraded is I. Soares: L-3 MAPPS employed its state-of-the-art instructor station complete. The integration of these models into the simulator with with advanced capabilities which will give the instructors better tools the legacy systems is currently ongoing and is due to be completed and greater capability to execute the various training programs. In by the end of July 2011. The bit to byte-wise conversion is also being addition, the conversion of the legacy assembler code and rehost completed. Pre-factory acceptance for phase II is scheduled to start to modern simulator servers will greatly improve the ease of on 26 July 2011 and factory acceptance on September 20. maintenance of the simulator. Finally, with the upgrade of the reactor simnews: What have been the major challenges in implementing core, NSSS, containment and HVAC models, this will significantly this project so far? expand the training capability of the simulator training scenarios and improve its fidelity. July 2011 | simnews | 9 projectperspective Real Teamwork The Key to Success in China Gregory Zakaib, L-3 MAPPS program manager, shares his perspective on two important projects that L-3 MAPPS took on in China recently. L-3 MAPPS has been in the power plant simulation business for almost 40 years. The experience gained as world leader in power plant simulation was essential to our recent work in China to develop the first full scope simulators (FSS) for their new build: first for Ling Ao Phase II nuclear power plant (NPP) in Guangdong Province and then for Hongyanhe Phase I NPP in Liaoning Province. In 2005, L-3 MAPPS was tasked with building the Ling Ao Phase II FSS using AREVA and Siemens digital control systems (DCS). Then in 2007, L-3 MAPPS was entrusted with developing a second pair of FSSs for the Hongyanhe NPP, the reference plant for follow-on CPR1000 projects under construction using DCSs from Mitsubishi Electric Corp. (MELCO) and China Techenergy Co. (CTEC). Both Ling Ao Phase II and Hongyanhe Phase I simulators support all training requirements and were available to prepare operators well before first fuel loading. Although the main purpose of the FSS projects was to develop training devices, throughout their implementation both simulators contributed to the deployment of the NPP’s DCSs by acting as “live” plant. L-3 MAPPS is not new to China. For over a decade, a series of high-performance, reliable simulators were delivered to China National Nuclear Corporation for the Qinshan Phase III plant and to China Guangdong Nuclear Power Company’s (CGNPC) Daya Bay and Ling Ao (Phase I) plants. The full scope simulators at Daya Bay and Ling Ao are being used for operator training six shifts per day at an availability of 99.8 percent (of uptime). The simulation technology has also been used for other applications, including technical support for the operating plants and emergency planning, among others. The projects required the integration of several technologies and deliverables from different vendors. It was a challenge for the teams – located all over the globe and spanning multiple cultural backgrounds – to collaborate, share knowledge and share work. Ling Ao Phase II FSS Project Leaders. From left to right: Qin Dexin (CNPEC), Ma Deyou (DNMC), Li Jinguang (DNMC), Doris Kittelmann (Siemens), Luigi Vindigni (L-3 MAPPS), Frederic Personeni (AREVA), Gregory Zakaib (L-3 MAPPS) , Sieghard Ewert (Siemens). Ling Ao Phase II FSS team during system integration in Montreal LHNP, CNPEC, MELCO, CTEC and L-3 MAPPS gather in 2009 for an Hongyanhe Phase I FSS project meeting in Montreal 12 | simnews | Issue 33 projectperspective Hongyanhe Phase I FSS contract signing ceremony with MELCO in Hong Kong (July 2007) 2009 Christmas dinner in Shenzhen hosted by L-3 MAPPS with friends from AREVA, Siemens, CNPEC and DNMC With the involvement of over 30 L-3 MAPPS engineers and 10 local subcontractor personnel, the project successes were rooted not only in the basic teamwork concept of cooperation, but also in the participants’ eagerness to learn something new – both technically as well as culturally – from their colleagues. Short and long-term expatriation benefits the individual in a variety of ways: skill transfer, managerial control and personal development. Even a short-term relocation provides invaluable experience, as often the only way to understand another business culture is to become immersed in it, particularly in growing economies such as China. In an era of videoconferencing and virtual meetings, distance is no longer a barrier to doing business. But succeeding internationally means more than just getting hold of people overseas. One must have a global mindset – a blend of experience, attitude and understanding of other cultures. The many projects L-3 MAPPS has delivered over the years and its experiences dealing with different cultures prepared us well for the challenges that lay ahead. When relationships between team members are built and confirmed on an ongoing basis, a culture of trust develops even when members are working away from one another. The way a group behaves and performs affects each of the individual members. When trust is present and group behavior is positive, each team member’s positive experience in turn leads to greater trust and ongoing participation. Because of the unique challenges confronting the CPR1000 teams which were not co-located, it was important to establish a strong foundation at the beginning of the projects to ensure that teams worked toward the same goals to ensure success. Extra efforts were needed to exploit the benefits of global teams while minimizing the disadvantages that arise from communication difficulties and a lack of physical contact. This was done by forging strong relationships between teams, building trust, celebrating rewarding experiences and having team members spend as much face time together as possible. The FSS projects presented an opportunity not only to integrate technologies, but to offer each team member the chance to travel and perform long-term localized assignments. Expatriate assignments Mongolian hut dinner in Beijing (July 2010): a great time for the L-3 were employed by all parties in various phases of the projects. MAPPS and MELCO teams Coming together is a beginning Keeping together is progress Working together is success - Henry Ford Hosting customers in workshops in Montreal during integration phases and scheduling team outings and events at the various sites often allowed the team members from each company to bond while learning about the local cultures. The successes of the CPR1000 FSS projects were a product not only of proven technology and technical know-how, but also of the triumphs and experiences gained by the team members. July 2011 | simnews | 13 technicaldevelopments Orchid® Touch Interface launched Earlier this year, L-3 MAPPS introduced Orchid® Touch Interface, an enhanced graphical user interface aimed at elevating our customers’ classroom training experience and at reducing the time demands on their full scope simulators. The first time that Orchid Touch Interface was demonstrated in a public forum was at the Utilities Service Alliance’s 2011 USA Nuclear Generator and Supplier Executive Summit which took place in Grapevine, Texas from 14 to 17 June 2011. The response to the new product was immensely positive. Offloading your full scope simulator with minimal USER INTERFACE investment Orchid® Touch Interface’s touch screen interface allows students to Is your full scope simulator in use around the clock? Do you have numerous young learners who have grown up in the electronic age and are more comfortable with interactive technology? Due to the high fidelity of your L-3 MAPPS simulation models, are there other “beyond training” demands on your full scope simulator (engineering support, exam development, pre-operation plant upgrade verification)? operate the panel graphics manually and obtain life-like visual and audible real-time responses. To keep training as realistic as possible, the popular panning and zooming of the soft panels in the instructor station are disabled for Orchid® Touch Interface, providing individual students and teams the opportunity to know the actual location and orientation of panel devices that are vital to operating your plant. Navigation can be L-3 MAPPS simulator users have already invested in their high fidelity performed from one panel to another without the risk of having an simulators with virtual panels which run on the instructor station and unrealistic layout of panel devices. which are also available in student mode. So, the answer to these In an environment where all panels are not visible at the same time, questions is to offload the demands on your full scope simulator off-view annunciators can be missed, creating a gap in training. With by reusing the exact simulation software and virtual panels with Orchid® Touch Interface, any time an off-screen alarm actuates Orchid Touch Interface without a significant investment. With new (annunciators located on panels in an area that the learner is not and improved large touch screen technology, L-3 MAPPS now brings presently looking at), an indicator appears to warn the student. With classroom training to another level with Orchid Touch Interface. a simple touch of that same indicator, an overview of the control room is displayed, indicating which panel is in alarm. From that same interface, the student can then navigate to it quickly. Ray shows off Orchid® Touch Interface 14 | simnews | Issue 33 technicaldevelopments ADVANTAGES •F ull-scale control room training environment at a fraction of the cost of your full scope simulator, capitalizing on the investment you have already made. • L ife-like training environment to augment your current full scope simulator environment, for both individual and team training. •O ffload your full scope simulator by using a device that fits the needs of young learners. • L -3 MAPPS’ client-server architecture guarantees realistic response times for all virtual panels, whether the simulated plant is in normal conditions or a severe transient is being experienced. • T ake full advantage of the powerful instructor station capabilities you already have through Orchid® Instructor Station with Orchid Touch Interface. •U se one bay of large touch screen monitors or reproduce the entire control room with multiple monitor bays. July 2011 | simnews | 15 infoexchange Bowled over at 2011 Conference in Tampa a range of delicious sides and topped off their energy reserves with some sweet treats for dessert. Diners then hit the lanes for a few rounds and a great time was had by all, with some bowlers revealing award-worthy bowling skills… The trophy for “Highest Individual Score” was awarded to Tom Luniewski (PG&E-Diablo Canyon), while “Most Improved Score” went to Bernhard Weiss (L-3 MAPPS). The “Most Creative Approach” honours were awarded to Jody Brodsky (STPNOC-South Texas Project) and Lisa Taylor (spouse of Dennis Based on customer feedback, the presentations were spread over Taylor (Duke Energy-McGuire)). Last but not least, the prestigious a two-day period with opening presentations beginning Thursday “Gutterball Award” was presented to Monika Lufi (spouse of Roger afternoon. Topics covered on day one included an overview of L-3 Lufi (Axpo-Beznau)) for this noteworthy achievement. Congratulations MAPPS Power Systems and Simulation projects and achievements in to all the award winners! 2010 and a briefing on the latest developments in customer service as well as an informative presentation of the latest technology updates. The annual North American edition of the L-3 MAPPS’ Owners Circle™ Conference (OCC) travelled to Tampa, Florida this year, taking place on Thursday, 17 February and Friday, 18 February 2011. The conference was again held in conjunction with the International Conference on Modeling and Simulation Technology for Power Plants (PowerPlantSim’11), which was held from 14 to 16 February. Thursday evening featured a networking dinner for conference participants and their guests. This year’s dinner included a fun-filled evening of dinner and bowling at Tampa’s Splitsville Luxury Lanes and Dinner Lounge. Bowlers fueled up on a variety of tasty entrees including filet mignon, mahi-mahi and chicken parmesan along with 16 | simnews | Issue 33 infoexchange The group reconvened Friday morning for a presentation covering migration to Orchid® followed by an informative guest presentation by Jody Brodsky, simulator supervisor of South Texas Project 1 & 2 at STP Nuclear Operating Co., titled “L-3 MAPPS’ IC Transfer Tool for Reactor Model Maintenance and the STP Experience.” This was followed by a live tool review that covered Orchid® Modeling Environment, Orchid® Configuration Manager, Orchid® Simulator Executive and Orchid® Instructor Station. Finally participants were briefed on the topic of Microsoft SharePoint for Document and Data Management before an opportunity for Q&A and open discussion brought the meeting to a close. L-3 MAPPS would like to thank all of the 2011 participants, with a special thank you to Jody Brodsky for his insightful guest presentation. We look forward to seeing you all back in San Diego for the 2012 conference. If you are a user of L-3 MAPPS simulation products and wish to join us for future Owners Circle™ conferences or if you would like to be a co-host, please contact Isis Lopez at [email protected] . July 2011 | simnews | 17 infoexchange Recent Events Since the last issue of simnews was published, L-3 MAPPS has been out and about at various conferences and tradeshows demonstrating its extensive Power Systems and Simulation know-how and technologies. A round up of the most recent events follows. The following are upcoming conferences, exhibitions an d seminars w here you can expect to mee t with L-3 MAP PS Power Systems and Simulation. CONTE 2011 L-3 MAPPS sponsored and exhibited at the American Nuclear Society’s 2011 Conference on Nuclear Training and Education (CONTE) which took place in Jacksonville, Florida on 6-9 February 2011. We also presented our solution for “ScenarioBased Testing and Training.” PowerPlantSim 2011 Immediately after CONTE 2011, L-3 MAPPS sponsored and participated at The Society for Modeling & Simulation International’s International Conference on Simulation Technology for Power Plants (PowerPlantSim). This event took place on 14-16 February 2011 in Tampa, Florida. L-3 MAPPS presentations covered four topics: • Scenario-Based Testing and Training • Use of Simulation to Support the Digital Feedwater Controls Replacement at the Callaway Plant • The Simulator Input/Output System: 2011 and Beyond • Implementation of Safety and Non-safety DCS on the Hongyanhe Simulator 14-17 August 2011 Location Organizer Participate October 2011 (date to be announced) Organizer Participate 28 September 2011 Location Participate 29 September-1 October 2011 2011 USA Nuclear Generator and Supplier Executive Summit L-3 MAPPS was pleased to sponsor and to exhibit at the Utilities Service Alliance’s 2011 USA Nuclear Generator and Supplier Executive Summit which occurred 14-17 June 2011 in Grapevine, Texas. It was the first time that L-3 MAPPS presented its Orchid® Touch Interface product at a public gathering. See the Technical Developments section in this issue of simnews for more on Orchid Touch Interface. 18 | simnews | Issue 33 Event Location Organizer Participate 12-15 February 2012 Event Location Organizer Participate 16-17 February 2012 Event Location OCI/OPG Suppliers Day 2011 L-3 MAPPS was on hand at the OCI/OPG Suppliers Day on 14 June 2011 in Ajax, Ontario. This event was put on by the Organization of CANDU Industries to allow industry suppliers to showcase their nuclear technology and services to Ontario Power Generation. Event Organizer POWER-GEN Europe 2011 The nineteenth POWER-GEN Europe Conference and Exhibition took place 7-9 June 2011 in Milan, Italy. L-3 MAPPS was on hand with a booth showcasing our power plant simulation solutions. POWER-GEN Europe 2011 had a record 14,917 attendees across the three events over three days. Event Location Nuclear 2011 In Shenzhen, Guangdong Province, China L-3 MAPPS exhibited at The 9th China International Exhibition on Nuclear Power Industry 2011 on 6-8 April 2011. This exhibition was organized by China Nuclear Energy Association (CNEA). Event Organizer Participate 16-17 February 2012 Event Location Organizer Participate 13-15 June 2012 Event Location Organizer Participate Utility Working Conference and Vendor Technology Expo Hollywood, Florida, USA American Nuclear Society www.new.ans.org/meetings/m_128 Owners Circle™ Conference Turku, Finland L-3 MAPPS By invitation; for L-3 MAPPS product owners/users OCI/AECL Suppliers Day 2011 Mississauga, Ontario, Canada Organization of CANDU Industries For OCI members only India Nuclear Energy 2011 Mumbai, India UBM India www.indianuclearenergy.net/ introduction.htm International Conference on Simulation Technology for Power Plants San Diego, California, USA SCS www.scs.org/powerplant Owners Circle™ Conference San Diego, California, USA L-3 MAPPS By invitation; for L-3 MAPPS product owners/users POWER-GEN Europe Cologne, Germany PennWell www.powergeneurope.com/index. html 2012 Nuclear Generator & Supplier Executive Summit Colorado Springs, Colorado, USA Utilities Services Alliance www.usainc.org lighterside COORDINATOR & GRAPHIC DESIGNER simnews would like to thank this André Rochon issue’s contributors: EDITOR R&R International Translation Specialists Inc. Milt Caplan (MZConsulting) Michael Chatlani Raymond Dimitri-Hakim Assad Hodhod Michelle McEwen Ilson Soares (Eletrobras Eletronuclear) Bernhard Weiss Gregory Zakaib simnews is a publication of L-3 Communications MAPPS Inc. www.L-3com.com/MAPPS © 2011 L-3 Communications MAPPS Inc. All Rights Reserved. ANTHEM, ANTHEM2000, AutoChart, CARDs, Chorus, COMET, Isis, jNet, Orchid, Owners Circle, ROSE, simnews, SimStudio and Visual Simex are trademarks of L-3 Communications MAPPS Inc. All other products are trademarks of their respective companies. L-3’s superior training environments use Orchid® simulation products to give plant operators the skills to handle any emergency response situation. No matter how complex or dangerous, any scenario can be reproduced, monitored and varied — realistically and in real time. To see how over 35 years of expertise in advanced simulation can make a very real difference to you today and tomorrow, visit www.L-3com.com/MAPPS. 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