Country ReportI&C Overview of NPPs at Pakistan

Waseem Uddin FarooqiDirector (I&C), DNPEP, PAEC

26th Meeting of the IAEA Technical Working Group

on Nuclear Power Plant Instrumentation and Control

24-26 May 2017

Vienna, Austria.

Presentation Layout

• Introduction

• Current Status of I&C in NPPs

• I&C Modernization in NPPs

• Modifications under FRAP

• R&D Project

• Recommendations

2

Nuclear Power Plant Sites

3

KANUPPsK-1, K-2 and K-3

CHASHNUPPsC-1, C-2, C-3 and C-4

NPPs in Pakistan

S. No. Name Location Capacity Type Date of CommercialOperation

1 KANUPP-1 (K-1) Karachi 137/98 MWe PHWR Dec. 1972

2 CHASHNUPP-1 (C-1) Chashma 325 MWe PWR Sep. 2000

3 CHASHNUPP-2 (C-2) Chashma 340 MWe PWR May 2011

4 CHASHNUPP-3 (C-3) Chashma 340 MWe PWR Dec. 2016

5 CHASHNUPP-4 (C-4) Chashma 340 MWe PWR Under Commissioning

6 KANUPP-2 (K-2) Karachi 1100 MWe PWR Under Construction

7 KANUPP-3 (K-3) Karachi 1100 MWe PWR Under Construction

4

Total Installed Capacity

5

Source: Power System Statistics, 2015-2016, 41st edition, NTDC

Generation (2015–16)

6

Source: Power System Statistics, 2015-2016, 41st edition, NTDC

Type MW Shares

Hydel 32,660 20.1%

Oil 7,760 4.8%

Gas 83,760 51.5%

Coal 19,910 12.2%

Nuclear 8,800 5.4%

Renewable 9,700 6.0%

Total 162,590 100.0%

Source: Planning Commission, Medium Term Development Framework, 2005-10

Electricity generation capacity in 2030

GOP Target for Nuclear Power in

Energy Security Plan

7

Current Status of I&C in NPPs

8

S. No. System C-1/C-2/C-3/C-4 K-2/K-3

1 Reactor Protection System

Two Loop System Architecture,Conventional, Hardwired, Modular

Three Loop enhanced System Architecture,Conventional, Hardwired, Modular

2 Nuclear Instrumentation System

2SR, 2IR, 4PR Neutron Detectors 4SR, 4IR, 4PR Neutron Detectors

3 In-Core Instrumentation System

Periodic Flux Monitoring, 30 locations, 03 Miniature fission chambers , 36 TC

Continues Flux Monitoring,44 locations, 7 Self powered neutron detectors per location, 46 TC

4 Process and Control System

Conventional sensors and transmitters, PID controllers, PLC/DCS Based Instrumentation in Conventional Island

Conventional sensors and transmitters, conventional controllers for safety, DCS based for non safety

Current Status of I&C in NPPs

9

S. No. System C-1/C-2/C-3/C-4 K-2/K-3

5 Plant Computer System

Plant Monitoring, Data Logging,Alarm Surveillance

Plant Monitoring & Control, Data Logging, Alarm Surveillance

6 Main Control Room System

Control: ConventionalMonitoring: Digital /Analog

Control: Analog/ DigitalMonitoring: DigitalComputerized Operating Procedures

Need for I&C Modernization

• Ageing & Obsolescence are major factor for I&C

modernization at NPPs

• Ageing is the degradation of I&C system /equipment

with time and use

• Obsolescence is the result of unavailability of spare

parts, loss of the suppliers, new regulatory requirements,

emerging technologies etc. 10

• Following major Up gradation were carried out at K-1:

1) Replacement of Plant Computer System

2) Replacement of Instrumentation Loops

3) Replacement of Process Information System

4) Replacement of Fuel Handling Computer

5) Installation of Fire Alarm System

6) Replacement of Metrological Instrumentation

7) Installation of Safety Parameter Display System

8) Installation of Post Accident Monitoring System

11

I&C Modernization Project at K-1

12

I&C Modernization Project at K-1

Fuel Manipulator Crane (FMC) at C-1

13

• FMC control system Upgradation was carried out during

RFO-07 (2011) indigenously by PAEC

• Old PLC based control system was upgraded by

advanced PLC & HMI with enhanced features

14

• MSR, Temperature Control System (RTC) Upgradation

was carried out during RFO-09 (2014) indigenously.

• Conventional modular system was replace by PLC

based advanced system with “Touch Panel” for HMI in

MCR

MSR RTC Up-gradation at C-1

15

• CPC HMI Station up-gradation was carried out during

RFO-09 (2014) indigenously by PAEC

• The color graphics terminal was replaced with HMI,

based on general purpose industrial computers

Plant Computer System (CPC) at C-1

March 1, 2016

16

• ETS up-gradation was carried out during RFO-10 (2016)

indigenously by PAEC

• Replacement of obsolete PLCs along with operator test

panel, with latest PLCs along with HMI

Emergency Turbine Trip System (ETS)

at C-1

17

• CRV Train-B was replaced during RFO-10 (2016) and

replacement of CRV Train-A is planned in RFO-11,

indigenously by PAEC

• Obsolete computer was replaced with advanced PLC &

HMI having Enhanced Features

Reactor Vessel Level

Monitoring System (CRV) at C-1

18

• CDA System was up-graded during RFO-10 (2016)

indigenously by PAEC

• The older system was replaced with FPGA based data

acquisition system

MCR Data Acquisition System (CDA)

at C-1

19

• CPF System was up-graded during RFO-10 (2016)

indigenously by PAEC

• The obsolete computer with DOS interface was replaced

with advanced embedded controllers

Plant Fire Detection, Alarm &

Protection Control System (CPF)

20

• Up-gradation of DEH is currently in progress during

RFO-11 ,carried out by PAEC & Shanghai Xinhua, China

• The older system will be replaced with advanced DCS

based system

DEH Up-gradation at C-1

I&C Modifications at C-2

• Addition of temperature monitoring of MG Set and other

cooling pumps on local panel & Plant Computer

• Addition of time delay in Reactor Coolant Pump (RCP)

upper bearing oil level low

• Replacement of In-core Nuclear Instrumentation System

distribution cabinet in reactor building

• Replacement of Circulating Cooling Water pump rubber

bearing and Cooling Water flow switches

• Replacement of RCP A/B thermal dispersion (FCI) level

switches with float type21

Fukushima Response Action Plan

• In response to Fukushima NPPs Accident PAEC

Corporate office developed and issued Fukushima

Response Action Plan (FRAP) for KANUPP and

CNPGS in August 2011

• Post Fukushima assessment of each nuclear power

plants was conducted as a part of FRAP

• Issues identified during the assessment were addressed

in the form of various activities to be undertaken at

C-1/C-2 and K-1

• In this regard following are some important electrical and

I&C related modifications carried out at NPPs

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FRAP

E&IC Modifications at K-1

23

• Environmental Gamma Radiation Monitoring (EGRM)

network installed

• An Emergency Control Center (ECC) is available on site

and Alternate Emergency Control Center (AECC) is

away from site

• Necessary plant documents / procedures are available at

AECC

• Satellite phone has also been made available beside the

already available land-line and mobile communication

facilities.

• Portable Diesel Generator(DG) is also available at AECC

FRAP

E&IC Modifications at K-1

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• Energization scheme of plant essential busses via

portable 300 kVA DG has been implemented

• A 375 kVA DG has been installed to energize essential

buses

• Energization scheme of essential buses through DGs (2

x 500 kVA) for extended SBO, has also been

implemented

• Installation of Accident Monitoring Instrumentation (AMI)

loops is in progress

FRAP

E&IC Modifications at K-1

25

• 230 VDC conserved from 01 hr to 07 hrs.

• DGs (2x100 kVA) installed (at higher elevation) for

continuous charging of station batteries

• Alternate power from 220 VAC UPS provided to medium

pressure ECCS MOVs

• Emergency lighting shifted from 230V DC to 220V AC

UPS to further conserve DC power

• Up-gradation of some fire alarm loops is underway

FRAP

E&IC Modifications at C-1/C-2

26

• One AECC exists at site, another is under consideration

further away from site

• Movable diesel generator are made available

• Alternate communication equipment is provided at MCRs

and also at ECCs

• Replacement of pneumatic type fire detectors with flame

detectors at Main and Auxiliary Transformer

FRAP

E&IC Modifications at C-1/C-2

27

• Installation of fire detectors in power cabinets

• A dedicated DG for use as DC Batteries charger with

hook-up arrangements has been installed

• A procedure “DC Load Shedding” is under preparation

which will be made part of SEOP, “Loss of all AC”

• Increased DC power capacity from 02 hours time to 07

hours

R&D Project on Smart Calibration &

Ageing

• To supplement the periodic maintenance, R&D of smart

calibration for I&C equipment is being conducted at

DNPEP, PAEC

• Mathematical model based estimation of calibration

related parameters of faulty equipment in I&C loops

• Abstract of the research work is already summited for

consideration in ISOFIC 2017

28

R&D Project on Smart Calibration

& Ageing

• Project Methodology

• Plant telemetry is acquired by the estimator

• Dynamic mathematical model is used to estimate the

equipment parameters

• Estimated values will show the effects of ageing and any

calibration requirements

• Project Benefits

• Online/offline analysis capability

• Enhanced process availability, low calibration /

maintenance workout, and improved ageing management

31-May-17

29

Recommendations to IAEA

• Guidelines on comparative and analytical aspects on

international codes & standards

• Digital I&C Systems review, evaluation, life cycle

management and V&V

• Digital MCR HFE design & review methods

• I&C aspects of computerized operator support systems

• Roadmap of Cyber Security implementation

• Cost effective I&C modernization techniques

• Active involvement of member states in the preparation &

review I&C related publications30

Special Thanks for Contributors

.

• Mr. Saeed –Ur– Rahman, GM (CNPGS)

• Mr. Sami Uddin, Director (NPS)

• Mr. Abdul Razzaq, Manager (I&C), C-1

• Mr. Maraj Khalid, Manager (I&C), C-2

• Mr. Muhammad Farooq, Manager (I&C), C-3

• Mr. Ahmed Yar, SE, DNPEP

• Mr. Aqeel ,SE, DNPEP

• Mr. Naveed A. Khan, SE, DNPEP

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April 2011 32