design and development of virtual panels for handling control room in pfbr simulator

www.ijnese.org International Journal of Nuclear Energy Science and Engineering Volume 4 Issue 1, March 2014 doi: 10.14355/ijnese.2014.0401.05

Design and Development of Virtual Panels for Handling Control Room in PFBR Simulator Bindu Sankar1, Jaideep Chakraborty2, Seetha H.3, Thirupurasundari D.4, Jayanthi T.5, Kuriakose K.K.6, Satya Murty S.A.V.7

Computer Division, Indira Gandhi Centre for Atomic Research Kalpakkam, Tamilnadu, India *[email protected]; [email protected]; [email protected] Abstract

The paper describes the design and development of Virtual Panels for Handing Control Room in full scope replica PFBR operator training simulator. Handling Control Room panels and consoles are used for Fuel Handling operations viz control and monitoring of fuel handling system. Handling Control Room consists of four control panels and four consoles. Virtual panels are used to emulate the real Handling Control Room panels/consoles and have the same layout as that of the actual plant. The hardware indicators, digital recorders, lamps, control switches, annunciation windows etc of hardware panels are replaced using software modules and they are graphically represented in 2D screen. The virtual panels are used for testing the process and logic models of fuel handling system in simulator.

Keywords

Prototype Fast Breeder Reactor; Virtual Panel; Full Scope Replica Simulator; Fuel Handling System

Introduction

Well trained operators are essential for plant safety in any Nuclear Power Industry. According to regulations of Atomic Energy Regulatory Board (AERB), operators need to be trained using Full Scope Replica Simulator. A Full Scope Replica Operator training simulator named KALBR-SIM was developed at Indira Gandhi Centre for Atomic Research at Kalpakkam, India. The scope of PFBR operator training simulator includes the modeling and simulation of all fuel handling equipments and their operations. Fuel handling system consists of two sub systems Invessel and Ex-vessel handling. In-vessel handling involves operations of Transfer Arm (TA), Large Rotatable Plug (LRP) and Small Rotatable Plug (SRP). Ex-vessel handling involves operations of huge equipments such as Inclined Fuel Transfer Machine (IFTM), cell transfer machine (CTM) etc. This paper is organized as follows.

The first section gives brief description of PFBR followed by hardware and software details of KALBR-SIM. Next section deals with handling control room layout and the operator actions performed there. This is followed by a brief introduction on process and logics models for fuel handling system. Next section explores the need for virtual panel modeling. The subsequent sections discusses in detail the design and development of virtual panel modeling and integration and testing of all models in simulator.

Brief Description of PFBR

Prototype Fast Breeder Power reactor (PFBR) is a pool type, sodium cooled, plutonium-uranium oxide fuelled, reactor with a thermal power of 1250 MWt and an electrical power output of 500 MWe. PFBR consists of three circuit’s namely Primary sodium, Secondary sodium and Steam - Water circuits. The primary sodium circuit consists of two sodium pumps and four numbers of Intermediate Heat Exchangers (IHX) inside the main vessel. The secondary sodium circuit consists of two identical loops each with a secondary sodium pump and four numbers of Steam Generator (SG). Steam and water system employs once through type steam generators producing super heated steam at very high temperature and pressure and adopts a reheat and regenerative cycle using live steam for reheating. To ensure safety, design with adequate safety margin, early detection of abnormal events to prevent accidents and mitigation of consequences of accidents, if any, is adopted.

Operator Training Simulator KALBR-SIM

KALBR-SIM Operator Training Simulator is a full-scope, replica type simulator which provides comprehensive training to operators in the PFBR plant

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International Journal of Nuclear Energy Science and Engineering Volume 4 Issue 1, March 2014 www.ijnese.org

operations. The simulator consists of mathematical models of PFBR subsystems running in a computer system to replicate the operational characteristics of the plant. PFBR Training Simulator is designed to simulate the steady state and dynamic responses of the plant in real-time to operator actions. The PFBR subsystems identified for simulation are Neutronics System, Primary Sodium System, Secondary Sodium System, Decay Heat Removal Systems, Steam Water System, Electrical Systems, Core monitoring and Fuel Handling systems. Refer Fig. 1 for systems developed by KALBR-SIM.

FIG. 1 SYSTEMS SIMULATED

Hardware Architecture of Simulator

The hardware architecture of PFBR operator Training Simulator KALBR -SIM is shown in Fig. 2, and consists of hardware panels and consoles, simulator server class computer, instructor station, input/output devices, simulator network and power supply respectively.

FIG. 2 HARDWARE ARCHITECTURE OF SIMULATOR

The Simulator server takes the role of plant and does various mathematical calculations to mimic the reactor in real time. It takes the input from the control panel/ consoles through I/O devices such as keyboard/ switches/button etc. After processing, the relevant outputs are displayed in devices such as indicators,

recorders, annunciation windows etc.

Software Architecture of Simulator

The software architecture of PFBR operator Training Simulator KALBR-SIM shown in Fig. 3 consists of the following components instructor, executive, logger , Database (DB) server, Messaging and Data Sharing Mechanism (MDSM), Logic model, virtual panel model, plant controls, Digital Control System (DCS) interface, Fuel Handling System(FHS) external model, input/output (I/O) panel interface which all are in UNIX platform. Fuel Handling process model and the interactive graphical user interface of fuel handling system is in windows environment. UDP socket based multithreaded framework based on client/server architecture for cross-platform data communication was used in full scope replica PFBR operator training simulator to communicate with the process models of FHS. Instructor provides the front end graphic user interface for communication by providing the facilities to control and monitor the simulator operation and conduct training sessions. Executive controls and synchronizes simulator components and is linked with the Instructor.

FIG. 3 SOFTWARE ARCHITECTURE OF SIMULATOR

Brief Description of Handling Control Room

Handling Control Room is separate from Main Control room where the regular reactor operations take place. The Handling Control Room houses all the human machine interfaces (HMI) pertaining to the control and monitoring of fuel handling operations.

HCR Layout

Handling Control Room consists of four control panels

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and four consoles. Handling Control Room location/ Layout is shown in Fig. 4. Each Handling Control Room panel and consoles are dedicated for fuel handling system operation. Panel 1/Console 1 are provided for TA and rotatable plug (RP) operations. Panel 2/Console 2 is provided for IFTM related operations. Panel 3/Console 3 is provided for Fresh Fuel Subassembly operation and finally Panel 4/Console 4 is provided for Spent Fuel Subassembly operation. Each panel/console also accommodates indicators, recorders, lamps, selector switches, annun-ciation windows etc.

FIG. 4 HANDLING CONTROL ROOM LOCATION

Operator Operations

The operator needs to perform fuel handling operations either at Handling Control Room panel or console depending on the equipment which needs to be handled. During normal fuel handling operations, all operations on Fuel Handling Equipments are carried out remotely from HCR panel, console, local control centres or directly from the field. The operator performs these operations either using switches or buttons provided in the panel/console or through soft command provided in display stations. The operator commands are executed by transmitting the commands digitally on the safety class 2 data highway. Operator can perform two types of operation during fuel handling operations viz, automatic or manual,

1) Automatic Selection

On selecting automatic sequence, the computer software guides the operator for each step. After completion of each step, the operator has to acknowledge it.

2) Manual Selection

On selection, manual sequence, the operator can execute the individual steps by himself through

hardware buttons. The operator can bypass any sequence provided the interlocks permit.

For example, the operations that can be performed from panel 1/console 1 are shown in table 1,

TABLE 1 TA/RP OPERATIONS

Sl.No. TA/RP operations performed from Console 1/Panel 1

Operation Type Operation Details

1 SRP rotation Clockwise rotation and anticlockwise rotation

2 LRP rotation Clockwise rotation and anticlockwise rotation

3 TA rotation Clockwise rotation and anticlockwise rotation

4 Guide tube translation Upward and Downward

movement

5 Gripper hoist translation Upward and Downward

movement

6 Gripper Finger Opening Outward and Inward

movement

Modeling and Simulation of Fuel Handling System

Modeling and simulation of fuel handling system for Full Scope Replica Operator Training Simulator involves process, logic and virtual panel modeling. This paper will concentrate more on virtual panel modeling. The process models are code intensive. The process models consisting of all fuel handling component operations are written using c++ in windows environment. The code can handle events and consists of engines, multithreading etc. Logic models are modeled using simulator tool. The main inputs are taken from design drawings, design and operation notes, process and instrumentation (P&I) drawings, general assembly (GA) drawings and discussion with design/system experts. The controls and interlocks were modeled using standard libraries like AND gate, OR gate, NOT gate etc. Application specific functional blocks were also created. The logic models were processed as per the set points and thresholds available in the requirement document. The output signals derived using logic models were used for controlling and providing interlocks.

Need for Virtual Panel

The developed simulator models can be tested using virtual panels. During the initial phase, the process models were developed. Later the logic models and finally virtual panels were developed. Some of the advantages of using virtual panel are listed below;

Cost Effective

They are excellent replacement of actual hardware

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panels as they are cost effective replacement. The cost of the software which can mimic the hardware panels is a pittance in comparison to the actual panel cost. The virtual panels can be made replica of the hardware panels in the sense that they can mimic the size, actual look and feel and physical properties of the equipment in a similar way. For example, if the push button in the actual hardware panel is a latch type then the same can be mimicked in the virtual panel too.

Informative and Attractive

The front panel of the entire virtual panel can be made more informative on their contents as this will depict the entire layout of handling control room. The virtual panel can be made more attractive by giving different colors for aesthetics. The controls and indicators can be made in different background (if needed) so that the operator can distinguish them at a glance itself. The alarm panel on encountering alarm or normal values mimics the same color code as used in actual hardware panel.

Excellent Test Bed

Developers can use the virtual panels and can view everything at a single place. Because of this, virtual panels are an excellent test bed. The system developers need not run around the hardware panel room for monitoring and control as it can be done at a single place itself and developers can fine tune the system before porting into the actual hardware panel.

Design and Development of Virtual Panel for Handling Control Room

Virtual Panel for Handling Control Room was developed using the simulator graphic tool. Virtual panel provides the human machine interface as they are identical with operator console and control room panels of the reference nuclear power plant. Design and development of virtual panel was done as per hardware panel/console drawings, annunciation window legend drawings etc. A virtual control panel consists of 2D screen graphically representing actual control elements such as buttons, switches etc and also they contain lamps, recorders etc which are used for monitoring purposes. The virtual panel controls can be operated by button clicks using mouse. The virtual panel consist of a main panel viewer and inside the viewer all the widgets or graphical objects are arranged hierarchically according to the layout of Handling Control Room panel/console. Each widget or graphical object was created using c code with

graphical libraries. Models consist of objects, their parts and their location. Models consist of single sub model or a group of sub models. To differentiate the models, individual unique names are assigned using the graphical editor so that they can be accessed during runtime by calling its name. Each model contains a set of attributes which are manipulated in the graphical editor or through the application c code. The development methodology adopted for virtual panel modeling is shown in Fig. 5. Indicators, Digital recorders, Lamps, Control switches, Annunciation windows etc were modeled and digital or analog variable names were associated with each model such that they get triggered when the simulator runs interactively with logic and process models.

FIG. 5 VIRTUAL PANEL DEVELOPMENT PROCESS

FIG. 6 VIRTUAL PANEL OF HCR

Handling Control Room Layout visualized in virtual panel is as shown in Fig. 6. On clicking the buttons 1, 2, 3 or 4 either from first or second row of Handling Control Room virtual panel layout, the relevant virtual screen will be displayed. For example, on clicking

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Button 1 in control Room panel, then the screen related to rotatable plugs and transfer arm will be displayed and one clicking console-2 button, the screen related to console 2 will get displayed. Each screen consists of three parts and is arranged according to alarm, controls and indicators.

Apart from virtual panel, there is also soft panel control for fuel handling equipments as shown in Fig. 7. This soft panel will be provided in display stations. The operator can either choose operation of equipment from virtual panel or through soft panel in display station GUI. The soft panel was designed using JAVA and integrated with virtual panel and simulator tool. For choosing soft panel operation for process, the operator has to choose computer guided (COMP) in the sequence selector switch. If the operator choose manual switch (MAN) the operator actions will be through virtual panel (ie hardware panel in the real plant).

FIG. 7 VIRTUAL PANEL VERSUS SOFT PANEL

FIG. 8 ROTATABLE PLUG AND TRANSFER ARM PANEL

DISPLAY SCREEN IN VIRTUAL PANEL

Transfer Arm and Rotatable Plugs Virtual Panel

In-vessel core handling includes transfer of subassemblies within the core. Access to every location over the core is provided with the help of LRP, SRP and TA. LRP and SRP are placed eccentric to each other and TA. Transfer arm is an offset type equipment. It is taken care that at any time, only one subassembly is handled in the core. Virtual panel

contains one screen for controls, one screen for display and two screens for displaying alarm annunciations. By clicking, the relevant buttons the screen changes. Rotatable plug and Transfer arm panel display screen in virtual panel is shown in Fig. 8.

Rotatable plug and Transfer arm panel control screen in virtual panel are shown in Fig. 9. In the display screen, the indicators are digital indicators such as LEDs, analog meters for showing the analog position, etc. In the control screen, the controls consists of on/off buttons, two way and three way selector switches, piano type gang switch etc. The layout of panel 1 of HCR consists of display screen, control screen and annunciation screens. The display screen is arranged in such a way that the operator gets useful and relevant information about the equipment being handled. The first row in the display screen consists of analog meters depicting the distance travelled and degree of rotation along with “Fuel handling operation authorized” indication. The second row consists of controls for transfer arm 3D video closed-circuit television (CCTV) manipulation for better viewing of the components. The third row is shown in yellow color consisting of LED lamp indication for guide tube and gripper hoist mechanism information. The final row indicates the top structure rotation information, gripper finger and rotatable plug operation information.

FIG. 9 ROTATABLE PLUG AND TRANSFER ARM PANEL

CONTROL SCREEN IN VIRTUAL PANEL

The control screen for rotatable plug and transfer arm panel consist of push button and key switches for operation of guide tube, gripper hoist, top structure rotation, gripper finger operation, motor emergency stop button, lock/unlock buttons etc. There are two annunciation screens containing alarm legends such as gripper hoist motor overload, high tension in hoist

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wire rope, system faulty etc arranged horizontally and vertically. Alarms get activated on encountering any abnormal operation. The alarms glow in red color to inform the operator about the malfunction.

Inclined Fuel Transfer Machine Virtual Panel

Inclined fuel transfer machine aids in transferring fresh sub assemblies from ex vessel transfer port (EVTP) to IVTP and spent sub assemblies from IVTP to EVTP. Ex vessel transfer port is in Fuel building and IVTP is inside the core in reactor containment building. The subassemblies which are handled by IFTM are absorber rods, blankets, fuel SA, reflector and shielding SA’s. IFTM contains two ramps namely primary and secondary ramp. The IFTM consist of primary ramp which ends in IVTP and secondary ramp which ends in EVTP. At the top, it contains rotatable shield leg (RSL) which can rotate clockwise or anti clockwise to align itself to one of the ramps. The transferring of fresh and spent sub assemblies via IFTM involves pulling up of transfer pot which contains either dummy sub assembly, fresh sub assembly or spent sub assembly. The transfer pot is pulled up through a pulley arrangement into RSL and then rotated to primary or secondary ramp so that the transfer pot can be lowered down to either IVTP or EVTP. Along the primary ramp, there is a primary gate valve and shield plug. Along the secondary ramp, there is secondary gate valve. These valves in the respective ramps get opened while the transfer pot is pulled up or lowered. The operations are sensed by many sensors like potentiometers, current transducers, thermocouples, switches, gamma detectors, pressure transmitters, flow transmitters etc. These sensor indicators are shown in the virtual panel. The operations to be carried out are in the form of key operated switches, gang switches etc. Alarm panel indicates the relevant alarm of the panel 2 like RSL motor overloads, system faulty etc.

Virtual panel for HCR console 2 showing controls, display and alarm annunciation screens is shown in Fig. 10.The panel 2 and console 2 of HCR consists of screens for display, annunciation and controls. The console 2 display screen consists of indicators which gives the position sensor values. The LED lamps indicate the transfer pot operation (lowering or raising), RSL rotation (towards primary ramp or secondary ramp), gate valves (open or close), shield plug (open or close) etc. Apart from this, the video coverage that is the CCTV capture of the actual components pan, tilt, zoom etc indication lamps are

also shown. The console 2 control screen consists of push buttons and gang switches which help in operation of the transfer pot lowering or raising along the primary/secondary ramp. The push buttons also aid in clockwise/anticlockwise rotation of RSL, opening/closing of primary gate valve, secondary gate valve or shield plug. These operations take place with aid of soft panel. For example, Fig. 11 shows the operation need to be performed from console 2 and panel 2 to lower the transfer pot along the primary ramp. The display screen of panel 2 shows the relevant glowing of LED lamps during execution and on completion of operations.

FIG. 10 VIRTUAL PANEL FOR HCR CONSOLE 2 SHOWING CONTROLS, DISPLAY AND ALARM

ANNUNCIATION SCREENS

FIG. 11 TRANSFER POT LOWERING THROUGH VIRTUAL

PANEL OPERATIONS

Fresh Fuel Sub Assembly Virtual Panel

Fresh sub assembly handling system consists of receipt, inspection, storage and loading of sub assembly into main vessel. Using Full Scope Replica Simulator, the operator needs to be trained to operate the fresh subassembly handling operation using the controls provided in Handling Control Room panel 3 and console 3. The scope of simulator for handling fresh fuel sub assemblies, consists of modeling fresh sub assembly transfer chamber, fresh sub assembly entry port and fresh subassembly pre heating facility.

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Apart from this, the CTM operations for handling fresh sub assemblies also need to be modeled in full scope replica simulator. All the other operations pertaining to handling the fresh sub assemblies such as, receipt, inspection, storage of fresh sub assemblies etc will be carried out locally at field. The transfer chamber is used for transporting fresh sub assembly from their storage in fresh subassembly storage bay to the nitrogen filled fuel transfer cell. Fresh sub assembly entry port is provided in the fuel transfer cell. Fuel transfer cell provides an inert (filled with nitrogen), shielded and leak tight cell during transfer of fresh or spent sub assemblies. There are three pre heating vessels and a plug storage vessel inside fuel transfer cell to preheat all types of subassemblies before loading into the reactor. The CTM, lifts the subassembly from the transfer chamber through the entry port to pre heating facility. The preheated subassembly is then transferred to EVTP located within the fuel transfer cell using CTM. Later with the help of IFTM, the sub assembly will be transferred into the reactor core.

Virtual panel display and control screens of fresh subassembly control panel is shown in Fig. 12. The first row in display screen of fresh sub assembly handling virtual panel, shows analog meters indicating CTM positions and subassembly (SA) weight. The CTM has to travel both horizontally along the rail as well as vertically (downward/upward) and hence there are two sets of values for coarse and fine positions. The subassemblies weight is shown in another analog meter display. The second row shows parameters such as zoom, pan, tilt etc of the CCTV camera kept in fuel transfer cell. There are also three analog meters displaying clock with stop watch value along with preheating vessel temperature and heater power in KW. The third row lists the various operation indications of CTM. There are two CTMs, each can either handle fresh fuel sub assembly or spent fuel subassembly depending on the choice made at console 3 or panel 3. Apart from this, there are other LED indicators, which shows the current status of valves, heaters etc. Through the control screen of virtual panel of HCR panel 3, the CTM operations, fuel handling startup operations and preheating facility operations are carried out through key switches and push buttons. Before starting any fuel handling operation, there is a prerequisite to satisfy sixteen fuel handling startup conditions. These conditions are monitored from panel 3, the relevant LED lamps and inhibition switches are present in panel 3. Once fuel handling startup gets authorized, a “fuel handling

operation authorized” LED lamp glows in all the panels and consoles, permitting the fuel handling operations.

FIG. 12 VIRTUAL PANEL DISPLAY AND CONTROL SCREENS OF

FRESH SUBASSEMBLY CONTROL PANEL

Spent Fuel Sub Assembly Virtual Panel

Modeling and simulation of Spent Fuel Sub Assembly Handling system is a part of development of PFBR operator Training simulator. Some of the equipment involved in this system are under water trolley (UWT), CTM, spent subassembly transfer machine etc. During fuel handling, the core subassemblies (Fuel & Blanket SA) are discharged from internal storage locations in the periphery of the core after their designed residence time, to an external storage. There are two identical CTMs provided over a common rail. One CTM is at fresh side and other is at spent side. The spent subassembly which reaches the EVTP through IFTM is handled by spent side CTM and transferred to washing facility. The spent SA coming out of the reactor core is wet with sodium. The entire spent SA has to be cleaned from sodium sticking to it before transfer to storage bay. The cleaning of spent SA is carried out at spent SA washing facility (SSWF), which is located in the fuel building within the fuel transfer cell. The spent SA are loaded into the UWT through spent SA exit port (SSEP). UWT receives the subassembly at higher elevation and delivers it at

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lower elevation within Spent Subassembly Storage Bay (SSSB). The display and control screen of the virtual panel of spent sub assembly handling system panel 4 is shown in Fig. 13. The first row contains analog meters showing the CTM and under water trolley positions along with sub assembly weight. The second row shows the video coverage indicators of spent SA transfer machines such as pan, tilt, zoom etc. The second column of the same row gives indication in more detail about the spent SA transfer machine positions, washing vessel temperature, clock with stop watch etc. The third row gives the complete information about the CTM which is similar to panel 3. The virtual panel through which the spent sub assembly handling is controlled is also shown below. The first column indicates the CTM control and the second column indicates the spent sub assembly washing facility controls. The other controls which are present in panel 4 are CTM drive emergency off push button, clicking which will stop the CTM operations, EVTP valve open/close etc.

FIG. 13 VIRTUAL PANEL DISPLAY AND CONTROL SCREEN

FOR SPENT SUBASSEMBLY OF CONTROL PANEL 4

Integration and Testing of Virtual Panel

The virtual panels were tested independently by forcing the relevant digital inputs to get expected

outputs and then integrated with the simulator and tested thoroughly. The integration with simulator tool is as shown in Fig. 14.

FIG. 14 INTEGRATION OF SIMULATOR TOOL WITH EXTERNAL

MODELS

The logic models and virtual panel models were modeled using the simulator tool and hence the data flow was through MDSM mechanism. These models were integrated with the process models and tested thoroughly. From instructor station, shutdown initial condition was loaded which mimics the shutdown state of the reactor. The fuel handling startup conditions were satisfied by feeding proper control inputs then the fuel handling system operations were started through virtual panel controls. The relevant indications and alarms were checked in the virtual panel display screen.

Conclusion

Training the operator is a mandatory requirement in any nuclear power plant. The operators cannot be trained in the actual plant as the safety is compromised. Keeping this in mind, the operators need to be trained in full scope replica simulator before they start controlling and operating the power plant from the main control room. Hence, there is a need to develop the operator training simulator. Each control panel in the main control room is provided with dedicated embedded system which communicates with the main simulation computer system through UDP sockets. The system developers before developing a full fledged full scope replica simulator need a test bed for testing the models with the control panel signals before porting into the simulator replica hardware panels. The excellent replacement for hardware panels are virtual panels. The control panel embedded system is emulated inside the virtual panel software so that the virtual panel behaves and communicates with the main simulation computer exactly like the actual control panel. Virtual panels are not only cost effective but they are very convenient for the system developers as they can control and monitor any system conveniently at a single place with button clicks. Hence the need for virtual panel has increased dramatically as the training

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of operators became mandatory. This paper discusses in detail the design and development of virtual panels used for fuel handling system of PFBR. The virtual panels are successfully used during the modeling and simulation of fuel handling system. Even after the integration of fuel handling simulator with the hardware panels, virtual panels are used while modifications are carried out. Also virtual panels are used as a supplementary during the operator training, for mimic display and demonstrations. Excellent feedbacks have been received on the utility of virtual panels during development, testing, modification and actual training.

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design and development of virtual panels for handling control room in pfbr simulator

Documents

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