ALL-RUSSIAN RESEARCH INSTITUTE FOR NUCLEAR POWER
PLANTS OPERATION
Analysis of Current State And
Progress Trends of PCS for
VVER NPP
Arkadov G.V. – Director General, JSC “VNIIAES”
Dunaev V.G. – Deputy Director General, JSC “VNIIAES”, Chief
Designer of NPP PCS
Bozhenkov O.L. – Deputy Chief Designer of NPP PCS
Seventh International Scientific And Technical Conference
«Safety, Efficiency And Economics of Nuclear Power Industry»
Moscow, VNIIAES, 26-27 May 2010
1
Evolutionary Progress of VVER NPP Automated
Process Control Systems
 The strategy of PCS development
accepted by the State Corporation
“Rosatom” is based on stepwise
(evolutionary) improvement of the design
solutions and implementation of the
requirements to NPP PCS under
absolute fulfillment of the Units’ start-up
directive dates.
2
Strategy of AES-2006 PCS Development (1/2)
 Technical solutions of PCS for Russian and foreign
NPP Units (Russian design) serve as the bases for
technical solutions of AES-2006 PCS: Kalinin NPP,
Unit 3, Tianwan NPP (China), Busher NPP (Iran),
Kudankulam NPP (India), as well as world
tendencies and requirements related to NPP PCS.
 Development and implementation of the specific
perspective and unified technical solutions on the
Units being upgraded and in the process of
completion will ensure reference of the design
solutions for AES-2006 PCS (NV NPP-2 and
LNPP-2).
3
Strategy of AES-2006 PCS Development (2/2)
 Already today the strategy of AES-2006 PCS
development is being implemented by the
corporation of the Russian enterprises via
stepwise introduction of the state-of-the-art
design solutions and software and hardware
complexes for PCS not only in the designs of
the Units in the process of completion and
construction (Rostov NPP, Unit 2, Kalinin NPP,
Unit 4, Beloyarskaya NPP, Unit 4), but during
the PCS upgrading on the operating NPPs
(Kola NPP,Units 3 и 4, Novovoronezh NPP,
Unit 5) as well.
4
НВАЭС-2
Калинин-4
Ростов-2
Evolutionary Progress of PCS
(Improvement of Design Solutions)
• System upper level structure id optimized
• Communication interface for connecting subsystems is unified
• Diagnostics of lower automatic control equipment is expanded
• PCS training facilities are implemented
• Unified local control panels
• New architecture solutions to exclude common cause failure of Unit
upper level systems’ functions
• In TPTS hardware a high-speed bus TPTS-EN is used
• Digital safety control system (technological)
• Reduction of cable connections between UCR and back-up shutdown
center and the rooms with lower automatics, improving of UCR and
BSC fire safety due to digital communications channel
• Unification of the subsystems upper level
• Diagnostics of electric-driven valves
• Digital Reactor Control and Protection System-Safety Control System
• 3rd level of NPP automation (Production CS)
• Transfer to up-to-date design standards
• Man-machine interface optimization
5
Current Tasks of AES-2006 Design
 Resolution of PCS design unification issues for NV NPP-2
and LNPP-2
 Verification of design solutions on Chief Designer test
facility in VNIIAES
 Finalization of soft- and hardware certification for RCPSSafety Control System, TPTS
 Development of e-designing for NPP PCS based on the
principles of system engineering
 Finalization of automated design system development for
control systems
 Joint development with Rostechnadzor of the guidelines
regarding PCS, satisfying the up-to-date world tendencies
6
NPP PCS Progress Trends in
VVER-TOI Design (1/4)
 Experience accumulated when creating PCS
designs for Kalinin NPP Units 3 and 4, Rostov NPP
Units 2 and 3, NV NPP-2, LNPP-2 and Beloyarskaya
NPP Unit 4, Tianwan NPP (China), Busher NPP (Iran),
Kudankulam (India), as well as NPP PCS world
trending allow to move on to the new stage in PCS
designing, which will be implemented when
developing VVER-TOI.
7
NPP PCS Progress Trends in
VVER-TOI Design (2/4)
 Functions ranking according to structural levels of PCS
architecture :
 Level 1: data receipt and primary processing, automatic
control/regulation
 Level 2: operational information display, solution of operational
rating tasks, remote control
 Level 3: analysis and accumulation of information about object,
solution of analytical tasks, data transfer to outer systems
 Integration of station monitoring and control systems in one
system of station upper level
 Use of display local control panels for local monitoring and
control systems unifying them by common bus
 Unification of primary systems, arranging of their information
exchange by common bus
 Implementation of digital safety control systems using the
principles of diversity of different types
8
NPP PCS Progress Trends in
VVER-TOI Design (3/4)
 Display method of monitoring and control using the
touchscreens for systems of normal operation
 Using display facilities for safety systems monitoring
 Implementation of SS components control under normal
operation using priority control module
 Using group display and digital control aids on UCR panels
 Minimizing the use of conventional control and monitoring
aids in UCR
 Reduction of cable connections scope between Unit Control
Room (back-up shutdown center) and the rooms with lower
automatics, improving of UCR and back-up shutdown center
fire safety due to digital (optical) communications channel
 Improving the automation and optimization level of process
control
9
NPP PCS Progress Trends in
VVER-TOI Design (4/4)
 Transfer from Unit process subsystems control to processes
control (functional design)
 Availability of tools for automated design and for testing the
normal operation and safety control systems
 Using the microprocessor-based aids on lower level
 Implementing the common system of integrated diagnostics
for process equipment, PCS facilities and processes,
supported by the corresponding methodology and instructions
 Man-machine interface optimization
 Using the unified soft- and hardware based on seriesproduced means
 Using the technology of PCS e-design based on the principles
of system engineering
10
Responsibility Distribution Over Stages of
PCS Life-Cycle
Area of AEP
Responsibility
Area of PCS Chief Designer Responsibility
Technical
Assignment for
Automation (AEP)
Development of
electronic PCS
technical design
Transfer of PCS as
a finished product
to commissioning
Integrated onsite testing of
entire PCS SW
and HW
Complex
Testing of edesign on ChD
test facility
PCS systems HW
delivery and
installation on
Unit
Development
of order to
plant manufacturer in eform
PCS systems
factory testing
Testing of PManufacturer
order on ChD
test facility
System HW
manufacturing by
the plantsmanufacturers
Area of ATE Responsibility
Participation in PCS
acceptance into trial
operation as part of Unit
PCS commissioning
activities combined with
Unit commissioning
activities
11
Design Solutions Verification
 PCS Chief Designer developed and commissioned a
special test site for testing PCS SW and HW tools and
complexes.
 Test programmes and methodologies are developed for
testing on Chief Designer’s test site and plantmanufacturers’ facilities.
 On test site the design process algorithms and manmachine interfaces being developed are checked in
different modes.
 By now, the following has been fulfilled on this test site:
testing of process algorithms for PCS of Rostov NPP
Unit 2, verification of assignments to plant-manufacturer
for PCS of Kalinin NPP Unit 4, testing of upper Unit
level system prior to shipping to Kalinin NPP.
12
Chief Designer Test Site for PCS in VNIIAES, Including AllMode Unit Model
13
Testing of Unit Upper Level System for Kalinin NPP Unit 4
on Chief Designer Test Site in VNIIAES
14
Development of NPP PCS E-Design
(Based On System Engineering Principles )
 Development and implementation of NPP RCS
e-design technology based on the system
engineering principles will ensure:
 Significant reduction of development period,
 Increase design quality,
 Competitive ability of PCS, in the export
designs including,
 PCS support at all life-cycle stages.
15
Technology of PCS Development Considering the
Requirements of System Engineering Standards
Advantages:
 Paperless technology and reducing PCS design
errors due to application of state-of-the-art
design tools.
 Elimination of errors by ASAP principle, and,
consequently, cost reduction.
 Obtaining adequate documentation at all stages
of PCS life-cycle.
 Significant reduction of costs for commissioning
activities due to elimination of PCS design
errors at earlier stages of development.
16
Works Arrangement on PCS Development and Delivery


Generation of technical policy relating the PCS
development is carried out by the Council of Chief
Designers of the Consortium and the section on
issues of PCS development and implementation in
the Directorate on Development and Realization of
AES-2006 Design
Development of a competitive Russian PCS in
frames of AES-2006 design is carried out using
maximum scientific and industrial potential of
nuclear weapon and energy complexes (NWC +
NEC)
17
Parties of Projects on PCS Development
System
Supplier
1
Normal operation and safety control
system (technological)
FSUE «VNIIA»
2
Control and protection system –
safety control system
JSC «VNIIAES» - AREVA
JSC «VNIIAES» - Rolls-Royce
3
In-core monitoring and diagnostic
system
JSC «VNIIAES» / RSC KI
4
Automated system of radiation
monitoring
JSC«SNIIP» / JSC «VNIIAES»
5
System of upper unit and station
levels
JSC «VNIIAES»
6
Fire protection monitoring and
control system
JSC«Tensor»
7
Auxiliary systems
(local panels)
FSUE «VNIIA» / JSC «VNIIAES»
18
International Cooperation
Work Arrangement With Foreign Partners
Order for
PCS
Complete delivery of
PCS and NPP CS
VNIIAES
System integration
AEP
SIEMENS
• Design
technology
Design
OKB GP
Site testing
• Componentry
• Training
АЭС
VNIIA
...
19
Ways of Involving New Project Partners
 The procedure for involving new project partners is
defined by the uniform Standard for Purchases,
authorized by the order of the State Corporation
“Rosatom” Director General.
 NPP PCS Chief Designer also participates in the
tenders, e.g., in the tender for LAES-2 PCS, which took
place in 2010.
 According to the Standard of Purchase, all
organizations, interested and having the corresponding
conditions, of any form of property, may submit their
bids for participation in the procedure of purchase of
PCS and/or subsystems and complexes, specifically, for
automation of Rostov NPP Unit 3 turbine hall.
20
Arrangement of NPP PCS Normative Base (1/4)
 Analysis of the Russian practice in development PCS is
based on sufficiently developed base of standards,
norms and regulations and demonstrates the following:
 Referring to standards, norms and regulations defining
the requirements to HW, there exist a high degree of
Russian and international standards’ requirements
correspondence. At the same time one should consider
that over 300 Russian standards relating to HW and
about 15 relating to SW are fully identical to IEC and ISO
standards;
 Referring to standards, norms and regulations defining
the requirements to SW, the Russian normative base is
insufficiently developed and does not satisfy the presentday requirements.
21
Arrangement of NPP PCS Normative Base (2/4)
 JSC “VNIIAES” elaborated proposals on application of
international IAEA and IEC standards to SW in PCS
designs of NPP Units under construction and design.
Proposals for introducing a package of standard
documents, international ones including, were discussed
with Rostechnadzor. These proposals are timely and
urgent in the context of changes in Federal Law № 184FZ, dated of 27 December 2002, “On Technical
Regulation” accepted at the initiative of the Russian
Federation President, determining a possibility of
acknowledging and using the international and foreign
standards and codes in the Russian Federation.
22
Arrangement of NPP PCS Normative Base (3/4)
 JSC “VNIIAES” in cooperation with Institut fur
Sicherheitstechnologie GmbH, Germany and Institutt for
Energiteknikk, Norway elaborated the first drafts of the
following normative documents:
 ”Nuclear Plants. Control Systems. Assessment of Software
Tools Quality and Reliability”;
 ”Nuclear Plants. Control Systems. Classification and
Qualification”;
 ”Nuclear Plants. Control Systems. General Requirements”.
 The above normative documents on development of
computer-based PCS may become the basis for elaboration of
federal safety norms and rules in the area of nuclear energy
use.
 The elaboration is carried out by joint efforts of the State
Corporation “Rosatom” organizations and Rostechnadzor.
23
Arrangement of NPP PCS Normative Base(4/4)
 JSC “VNIIAES” elaborated a package of guidelines, defining
requirements to new generation of PCS on the basis of SW
and programmable facilities, requirements to testing,
verification, validation, qualification and certification, five of
which are submitted for approval to JSC “Atomenergoproject”,
JSC “SPbAEP”, RSC “Kurchatov Institute”, JSC OKB
“Gidropress”
 In February 2010 the first draft of the guideline “Nuclear
Plants. Control Systems. Stages and Phases of Development.
General Provisions” was elaborated and distributed for review,
where the requirements are set out to all stages and phases of
PCS development and introduction, to the composition and
contents of the documents at all stages and phases.
24
Conclusions (1/2)
 The Russian enterprises have sufficiently great scientific and
industrial potential for creation of competitive Russian PCS,
which allows us today together with foreign companies to
ensure the world scientific and technical level of NPP PCS, and
in the near future to compete with the West on equal terms in
the area if information technologies.
 JSC “VNIIAES” in cooperation with the industry enterprises
elaborated, introduced and currently are improving and
introducing state-of-the-art control systems of in-house design,
well comparable with foreign analogues; the PCS test site is
functioning.
 In the industry a complex of activities is being implemented on
improving the works on development and introduction of a
competitive Russian PCS, specifically, in frames of standard
design of optimized and informatized VVER Unit (VVER-TOI).
25
Conclusions (2/2)
 Technical and commercial proposals were prepared to
participate in tenders on supply and putting into operation of
PCS for NPP of Russian design (NPP in Turkey, India,
Czechia, Hungary).
 Currently a new enterprise JSC “VNIIASU” is in the process
of creation in the interests of the industry to perform the
development and complete supply of “turnkey” PCS for the
NPPs being finished and the NPPs of new generation.
 An up-to-date normative base is under arrangement for NPP
PCS development and introduction based on computing
machinery and harmonized with the international standards
26