28/10/2014 AS-74.1101 Tietokonesimulointi Utilization of Apros Simulation Software in Loviisa Power Plant I&C Renewal Vesa-Matti Tikkala 29.10.2014 Outline • • • • • Introduction Fortum Apros Simulation Software Loviisa NPP Automation renewal Case: Simulators in Loviisa Nuclear Power Plant Instrumentation & Control renewal – Operator training simulator – Engineering and development simulator • Conclusions/discussion 2 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 1 28/10/2014 Fortum in general Power and Technology Heat, Electricity Sales and Solutions Russia Distribution • Hydro, nuclear and thermal power generation • Power Solutions with expert services • Portfolio management and trading • Technology and R&D functions • Combined heat and power (CHP) production • District heating activities and business to business heating solutions • Solar business • Electricity sales and related customer offering • Corporate Sustainability • Power and heat generation and sales in Russia • Includes OAO Fortum and Fortum’s slightly over 25% holding in TGC-1 • Electricity distribution activities The segment incorporates two divisions: • Hydro Power and Technology • Nuclear and Thermal Power 3 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Our geographical presence Power generation Heat Distribution Electricity sales Nordic countries Key figures 2013* Power generation* 46.5 TWh Heat sales* 13.9 TWh Distribution customers in Sweden 0.9 million Sales EUR 6.1 bn Operating profit EUR 1.7 bn Balance sheet EUR 23 bn Personnel 9,900 Electricity customers 1.2 million Russia OAO Fortum Power generation 20.0 TWh Heat sales 24.2 TWh Great Britain In addition, ~25% share in TGC-1 Power generation 1.0 TWh Heat sales 1.8 TWh Poland Baltic countries India Power generation 0.6 TWh Heat sales 4.0 TWh Power generation Heat sales Power generation 0.5 TWh 1.1 TWh ~9 GWh * incl. Fortum Värme; power generation 1.3 TWh and heat sales 8.2 TWh. 4 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 2 28/10/2014 Nuclear power* capacity Nuclear power MW Fully-owned Loviisa 992 Co-owned Olkiluoto (TVO) 468 Oskarshamn 1 089 Forsmark 699 Total 3 248 • A fully-owned nuclear power plant in Loviisa • Co-owned nuclear assets: • • • 26.6% interest in TVO’s power plant units in Olkiluoto, Finland. 22% interest in the Forsmark units, Sweden 43.4% interest in the Oskarshamn units, Sweden Olkiluoto Loviisa Forsmark Helsinki Stockholm Oskarshamn * Power capacity refers respectively to Fortum's shares of fully and jointly-owned power plants. 5 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala APROS - Advanced PROcess Simulator APROS development • Developed by Fortum and Technical Research Centre of Finland (VTT) • Development started 1986 • Commitment to continuous development http://www.apros.fi 6 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 3 28/10/2014 APROS - Advanced PROcess Simulator 7 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Apros applications Apros has users in 26 countries • Power plants • Engineering offices • Safety authorities • Research organizations • Universities 8 Industries Applications • Nuclear Power • Engineering • Combustion Power • Safety Analysis • Pulp and Paper • Training Simulators • Desalination Applications • Training and Education • Solid Oxide Fuel Cells • Automation Testing • District heating • Research and Development 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 4 28/10/2014 APROS Multifunctional simulator 9 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Simulation system NUCLEAR REACTOR AUTOMATION SYSTEM GRAPHICAL USER INTERFACE BOILER MODELS THERMAL HYDRAULICS APROS SIMULATION ENVIRONMENT 10 29.10.2014 SIMULATION DATABASE THERMAL POWER PLANT ANALYSER NUCLEAR POWER PLANT ANALYSER INSTRUCTOR CONSOLE ELECTRICAL SYSTEMS TRAINING SIMULATOR CONTROL ROOM Fortum Oyj / Vesa-Matti Tikkala 5 28/10/2014 Component definition levels Process level User’s main operation level: Process component level APROS generates : Calculation level Elementary components branches, nodes, structures, Source:[1] 11 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Calculation principles Governing Equations • Mass balance • Momentum balance • Energy balance Source:[2] 12 Calculation is hidden from the user User can tune the model using various parameters Governing Equations, Discretization, Linearization, Solution Principle, Source terms, Hydraulic Diameter, Roughness of pipe, Loss Coefficients, … 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 6 28/10/2014 Calculation Models Thermal hydraulics • 3-Equation model • 5-Equation model Reactor models • Point kinetics model • One-dimensional model • Three-dimensional model • 6-Equation model Heat structures Containment models • One-dimensional heat conduction • Cartesian • Cylindrical • Spherical 13 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Basic process components • • • • • Connection point Tank Pipe Valve Pump • Heat exchanger • Turbine section • Condenser • Combination • Throttle • Heat structure See more:[4] 14 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 7 28/10/2014 Boiler components • • • • • Compressor Gas turbine Heat exchanger Axial and radial fan Fluidized bed Possible fluid substances • Coal • Natural gas • Oil • Air • Water and steam • Flue gas Combustion reactions and the concentrations of reaction products are solved 15 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Nuclear power plant components • • • • • 16 Reactor Pressurizer Horizontal and vertical steam generator Accumulator Containment components (node, branch etc.) 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 8 28/10/2014 Automation components • Three main groups – Measurement Control circuits logic circuits sequence program change over automatics – Control and logic system – Interface to the controlled devices • More than 50 elementary components available Measurement system Position Interface to the controlled devices Process 17 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Electrical components • • • • • • Busbar Switch Load Generator Transformer Line • Process components are connected to busbars • APROS solves voltages, currents, frequencies, active and reactive powers • Synchronization, excitation, diesel generators and directed current 18 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 9 28/10/2014 Communication with external systems • Open and easy connection for external routines • ACL • OPC • External model Automation system GUI OPC In-house unit model ACL DLL APROS Data file 19 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Loviisa nuclear power plant (NPP) • The plant units have been running since years 1977 and 1980 using mostly original I&C • Pressurized Water Reactor (PWR) – Primary side – Secondary side • Safety – Redundancy – Physical separation – Diversity • Operating principle – Fail safe design 20 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 10 28/10/2014 Loviisa NPP I&C renewal • Loviisa NPP is going through an instrumentation and control (I&C) renewal project to ensure the availability of the plant until the end of the lifetime. • The I&C renewal project was originally started in year 2005 – A new direction was adopted in 2014 • I&C renewal will be carried out in stages • Installations are done during the normal annual outages – Final installations in 2018 • Suppliers – Rolls-Royce – Metso 21 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Simulators in Loviisa NPP I&C renewal • Training simulator • Engineering and development simulator • Model for safety analysis and design studies 22 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 11 28/10/2014 Model development for training and E&D simulators • Model development was started in year 2005 • Safety analysis model was used as a basis -> extension of scope • Main processes, most of the auxiliary processes, automation and electrical power systems are modelled • Requirements: – Real time simulation speed, accuracy, multiple applications • Acceptance Criteria – Pre-selected transients • • • • 23 ~ 120000 binary signals ~ 28000 analogue signals ~ 6000 thermal hydraulic nodes ~ 50000 automation I/Os 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Simulator training • US Nuclear Regulatory Commission (NRC): – Even 65% of the accident happening in the Nuclear Power Plants happens due to Human Factors • Finnish Radiation and Nuclear Safety Authority (STUK): – Simulator training shall be part of the initial and refresher training given to operators who manipulate the reactor controls in the control room. – The simulator facility must be as representative of the plant main control room as possible. – The simulator's behaviour during transient and accident conditions shall adequately well correspond to the plant's behaviour and the range simulated shall cover plant normal operation, operational transients and accidents in the extent appropriate. • Training topics in simulator – Malfunctions and failures – Operating procedures – Events from Loviisa or from other plants 24 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 12 28/10/2014 Training simulator • Important part of basic training and in yearly continuing training • Training simulator must be adopted to the changes in the plant – especially in the control room. • Loviisa NPP Training Simulator is updated alongside I&C renewal – New I&C system and monitor based control room – New Apros models • Training simulator renewal follows stages of I&C renewal 25 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala Apros in focus of new Loviisa power plant simulators Instructor's Station Apros 29.10.2014 Metso DNA Monitoring system 6eq primary circuit Exceeds present FSS extent 3eq secondary circuit App. 60 process systems Containment App. 6000 TH -nodes 3D reactor model New Safety Panels 26 Spinline New safety I&C Parallel processing 12 Apros processes ABB process computer system Fortum Oyj / Vesa-Matti Tikkala 13 28/10/2014 E&D simulator - Development of new HMI systems and training simulator • Goal is to assist – Design of new HMI – Development and integration of the new Loviisa NPP • Extensive process model tests • Testing and development of new training simulator – Interfaces and communication between the components – New components 27 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala E&D simulator – HMI and operating procedure design and testing • Simulator assisted Human Machine Interface (HMI) and Operating Procedure design and testing – Large Screen Displays – Reactor Protection System (RPS ) and long term protection system (LPS) HMI pre-validation • Functionalities can be seen and tested before installations The Fortum E&D simulator is a very suitable tool for the testing of systems usability of the new design at those stages in which the training simulator is not yet available. The tests provided useful information for the further development of the HMIs and gave valuable insights of the ways the operators monitor and control the process according the new concept -Jari Laarni, Systems Usability VTT Technical Research Centre of Finland - 28 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 14 28/10/2014 E&D simulator - Development of new training simulator Instructors Interface 29 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala E&D simulator – Testing of process model • Testing of process model – Whole process model is tested in various tests – In co-operation with Loviisa NPP operators • E&D simulator enables tests where manual operations from operators are needed. • Feedback from the plant personnel • Model is tested in iterations 30 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala 15 28/10/2014 Conclusions • Apros simulator is available for dynamic simulation of process systems • Extensive use of simulators in Loviisa automation renewal – Engineering and development simulator – Second training simulator LOKS 2 will be build • Same process model used in several applications • Efforts to improve process models and tools – APROS, Testing Station • Experience from LARA stage 1 – Good results in using simulator • HMI display design -> operators involved early on • Closed loop I&C testing -> even initial data faults corrected 31 29.10.2014 Fortum Oyj / Vesa-Matti Tikkala References 32 [1] Apros overview, http://www.apros.fi [2] Hänninen, M., ”Phenomenological extension to APROS six-exuation model”, 2009 available:http://www.vtt.fi/inf/pdf/publications/2009/P720.pdf [3] Overview of thermal hydraulic models, http://www.apros.fi [4] Component libraries, http://www.apros.fi [5] Communication, http://www.apros.fi [6] Tahvonen, T., Laakso, P., Wittig, J., Hammerich, K., “Simulation assisted automation testing”, Presented in IFAC Symposium on Power Plants and Power Systems Control, 5-8 July 2009, Tampere, Finland [7] Näveri, J., Tahvonen, T., Hakasaari, P., “Testing and Utilization of Loviisa Full Scope Apros Model in Engineering development Simulator”, 12-18.8.2010, Cape Town, South Africa 29.10.2014 and Fortum Oyj / Vesa-Matti Tikkala 16
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