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ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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The times of Nuclear Simulators
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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CORYS Overview
Revenues
R&D effort
Staff
35 M€
7% / year
220
36%
32%
22%
9% France
Americas
Europ, Middle East, Africa (EMEA)
Asia & Australia
2015
Activity fields
Zones Shareholders
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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World leading company for
Nuclear power plant simulators
Customers
› Electrical Utilities
› Training centres
› System integrators
Fields
Power simulation
Corporate presentation
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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History of Average Nuclear Reactor Construction Time
Source: IAEA « Nuclear Power Reactors in the World – Edition 2011
4
86 131 85 29 23 20 7
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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1st concrete
2009 2010 2012 2012 2013
Civil Engineering works
Reactor Vessel
2014 2008
Commercial Operation
Electro-mechanical equipments
Commissioning tests
Total Construction Time : 52 months
Site preparatory works
DAC Authorization
TSN1 Original Construction Schedule
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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The Training FSS and Plant Construction schedule
4W Sim
14 W /
4 W FSS
10 W /
4 W FSS
21 W /
8 W FSS
2 W /
1 W FSS
Challenging Time constraints issues All Operator Crews to be licenses before “Fuel Core Loading”
(Requirement from Regulatory Bodies in all countries)
One-Year minimum to train & license Operators on FSS
FSS to be “Ready for Training” on June 2012
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Taishan Full-Scope Training original schedule
7
01/09/2009 31/07/2012
01/01/2010 01/01/2011 01/01/2012
26/11/2009 - 02/03/2010
General Design
06/04/2011 - 12/07/2011
Integration DCS Databases30/06/2012
RFT
02/03/2010 - 07/04/2011
Detailed Design and Developments
07/04/2011 - 30/12/2011
FSS Integration & Pre-FAT
01/09/2009
EOC
01/09/2009 - 25/11/2009
Project Set Up
05/06/2010 - 23/09/2011
Hardware Activities
25/01/2012 - 29/06/2012
FAT & SAT (Taishan)
29/10/2011 - 24/01/2012
Shipment & Erection
Design
Tuning &
PreFAT
TXS- Emulation
SPPA-T2000
Emulator
SICS
Dev/Int.
I.S.
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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The « Dig through mounds » impossible objective ….
« Everquest Lanmark » an online sandbox where you can design
and build anything from your pickaxe
The studio initially announced it had “set out to make something
revolutionary”
Unfortunately, as they put together the pieces, they found that it
wasn’t fun
The game
never came
Online
8
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Taishan FSS project overview
Plant Process Models
DB
Simulation
INS
TR
UC
TO
R
STA
TIO
N
NSSS Containement CI / BOP ELX 3D Core NI
Project Main
characteristics
Contract Signing:
Dec ’2009
Customer: CNPEC
Advanced two-phase
flow modeling on
RCS/ECCS/CVCS/ Main
Steam and FW
256 plant systems
included in FSS scope
Control room stimulation
DCS emulation
Back-up panel
stimulation
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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TSN FSS : who delivers what (simplified)
Yellow = CORYS
Red = ANP
Blue = SIEMENS
Purple = DEF
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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A glimpse of the Complexity of FSS for new build
Simulation scope estimation
6,000 valves
400 pumps, 400 fans
700 motors, 500 breakers, 50 transformers
300 heat exchangers, 350 filters
300 tanks
13,000 alarms, 900 local commands
30,000 I&C objects
Plant parameter database
500,000 parameters
1,200 documents for initial delivery
4,000 documents / 100,000 pages foreseen
Multi-site FSS development
CORYS Grenoble
CORYS Beijing
Client site Taishan
AREVA SAS & GmbH
Data Package delivery
Initially scheduled through 5 separate batches
Finally followed up through 1 600 separate milestones
8-months average delay after 1-year of project …
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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FSS situation overview
Mitigation plan developed to enable Emulated I&C integration
Plant System thermal hydraulic models developed and integrated, using a preliminary I&C simulated version – PreFAT completed since June 2012
Core Model is successfully Acceptance Tested
FSS/SPPA architecture developed and integrated .
Multiple FSS hardware configuration made available, on simulation and emulation platforms.
Years of V&V tests passed with RC1+ versions (90% simulated, 10% emulator)
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Number of Discrepancy reports solved
DR solved
DR open
Under correction
V&V phase
preFAT
Tuning phase
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Customer Benefits
Intimate scheduling of I&C design
and FSS activities
Validate I&C and SMD design along with
engineering development
Early validation of Operator Station HMI
Train future operators
Simulation for Nuclear projects – Recommendations
Reference
Plant
Simulator
V&V and
Pre-TRAINING
SIMULATORS
PLANT REPLICA
FULL-SCOPE
TRAINING
SIMULATORS
Stand-Alone
I&C
Verification
Mini
simulator
Engineering
Platforms
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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CORYS simulation solutions before FSS
Operation, performance, HFE, Commissioning …
Process
model A
I&C
model A
Integrated
model A
Process
model B I&C
model B
Integrated
model B
Multi-system
Simulation platform
System A System B
Expert
tests
Reference
scenarios
Funct.
scenarios
Integration tests
« Closed loop » dyn tests
…
Data test
(coherence, completeness)
« open loop » dyn. tests
…
Expert
tests
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Overall Engineering sequence
Basic Design I&C diagrams
Process Function Diagrams (PFD)
Architect Engineer
DCS Vendor
Application software
F . A . T .
-
System Engineering
Design Manual
Integration tests
Software Detailed
Engineering
Software Basic
Engineering
I&C System
Engineering
Hardware Engineering Hardware Purchasing
and Manufacturing Hardware F . A . T .
Power plant Construction project
V&V on I&C
Functional
Diagrams
V&V on I&C
detailed
diagrams
V&V
in
Closed
Loop
Improvement Feed-Back into CAD system
Plant Systems
/ I&C
Integrated
Validation
I&C hardware
Test
Bench
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Taishan 1&2 EPR Project
Major Milestones
17
First Concrete
TS2 Nuclear Reactor
Engineering
created
2008 2013 2010 2012 2009 2011
Signature of
the Contract First
Concrete TS1
TS1
1st liner lifted
TS2
1st liner lifted
© Copyright TNPJVC
TS2:
Dome lifted
2014
TS1
Installation of
RPV internals
2016
TS1: Primary
loop welded
TS2: 1st SG
delivered
TS1:
Dome lifted
TS1:
RPV installed
TS1
CFT Successful
completion
2015
TS1:1st EDG
available
TS2: Primary
loop welded
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Taishan simulator projects status
First Simulator
First version installed
in July 2010, updated
twice afterwards
100 Operators,
supervised by 11
instructors, initially
training
80 scenarios , 12-
week program, 12 000
hours delivered
18
Training FSS
RFT signed on Sept
27th 2014, then received
NNSA license
Successful completion
of RO examination in
Dec, ‘14
Successful completion
of SRO examination in
May, ‘15
2000 training drills
delivered, 21.5
hours/day, 7 days/wk
Engineering Simulator
March 2015 1st version
installed
June 2015, HFT NI I&C
upgrade
Dec 2015, CFT
procedures validation
June 2016, HFT NI
I&C upgrade
ATOMS FOR THE FUTURE 2016 – Simulators and New Build Projects
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Questions ?
Taishan Unit 1 Cold Functional Test (CFT) was successfully
completed on Jan. 27th, 2016
Achieved result