I&C Status at EDF & Recommendations to IAEA

1. I&C Status at EDF&Recommendationsto IAEA IAEA TWG-NPPIC Meeting20-22 May 2009Vienna Patrick Salaün – EDF

2. EDF Nuclear Power Plants Studies concerning the I&C Systems

3. Penly Gravelines Paluel Chooz Cattenom Flamanville Nogent Fessemheim Dampierre Chinon St-Laurent Civaux Belleville Bugey Le Blayais Golfech St-Alban Cruas Tricastin Nuclear Power Plants at EDF, in France • PWR 900 MW series : 34 units • 6 CP0, 18 CP1, 10 CP2 units • Connection to the grid: 1977 - 1988 • 3rd ten-yearly outage: 2008 - 2018 • PWR 1300 MW series : 20 Units • 6 P4 / 14 P’4 units • Connection to the grid: 1985 - 1994 • 2nd ten-yearly outage: 2005 - 2013 • 3rd ten-yearly outage: 2015 - 2023 • PWR 1450 MW (N4) series : 4 units • Connection to the grid: 1996 - 1999 • 1st ten-yearly outage: 2008 - 2010 • PWR EPR series : • The first unit currently being built • Full series: built after a few years of operation of the first of the series  I&C unlikely to be exactly the same Approx. 80% of electricity production IAEA TWG-NPPIC Meeting

4. Nuclear Power Plants at EDF, in United Kingdom From British Energy (part of EDF S.A.) • CGR : • 410 MW : 4 UnitsConnection to the grid : 1976 – 1977 • 520 MW : 2 UnitsConnection to the grid : 1983 - 1985 • 585 MW : 4 UnitsConnection to the grid : 1983 - 1984 • 615 MW : 4 UnitsConnection to the grid : 1988 - 1989 • PWR 1190 MW : 1 unit • Connection to the grid: 1995 • PWR EPR series : • 7 potential sites  I&C unlikely to be exactly the same Approx. 20% of electricity production IAEA TWG-NPPIC Meeting

5. On-going I&C-related activities at the NPP’s, in France • Regarding EPR • in Flamanville : • Architecture design validation, Allocation of functions, Safety Assessment … • In UK • Discussion with HSE, NII : EPR I&C Design acceptance • Regarding the 58 existing plants in France • 3rd ten-yearly outage for the 900 MW in progress : • e.g. Modernization of the Rod control System : PLCs and FPGA-based modules. • 1st ten-yearly outage for the 1450 MW in progress : No I&C modification • 3rd ten-yearly outage for the 1300 MW : • Aging & Obsolescence studies : “health” assessment of the current I&C systems (2007-2008) • Plant Performance studies : operation, maintenance, availability, power generation…. • Feasibility studies (technique, budget, delay) for some important/critical systems (according to the strategic objectives) : in progress IAEA TWG-NPPIC Meeting

6. 20 . 06 20 . 07 20 . 08 20 . 09 20 10 20 11 20 12 20 13 20 14 20 15 20 16 20 17 Phase Projet DDV 1 Revue APS M2C Clôture Lot suite Orientation OVCC 1300 2 GPR Réexamen Rénov. CC 3 Revue M2C Phase Stratégique Etudes stratégiq ues 4 Décisions Directoires 5 J0-18 J0-9 Finalisation 6 D J0 J1 J2 Généralisation Etudes de Réalisation VD3 e-DIM TTS Intégration Parc 7 12 m. Mini Phase 8 Cahiers des charges réalisation 9 ACHATS validation lots achats 10 Etudes réalisation REX J0-33 Doc Exploit Réalisation 13 Documentation Exploitation ASN 14 J0-12 Lettre EDF DDV 15 Approb. Modifs logicielles J0-27 Processus 16 Lettre DPI Déclaration à l'ASN de l'ensemble des modifs VD3 1300 ASN 17 DA disponible 18 lettre périmètre du lot J1+12 Avis ASN sur rapport d'examen Rapport de Sûreté P4 P'4 19 GPR Orientations 20 GPR Thématiques GPR Réexamen GPR Clôture Examen de Principes de Définition du Préparation du Réalisations des contrôles TTS 21 Conformité l'ECOT Contour Programme sites et corrections de 22 Présentation à l'ASN Etudes Correctives Réalisation Planning of the 1300 MW ten-yearly outage IAEA TWG-NPPIC Meeting

7. Strategic objectives regarding NPPs at EDF • Achieve maximum plant useful life • Current planned lifetime for existing plants: 40 years • When possible and cost-effective, extension to up to 60 years • Not all plants will be extended beyond 40 years • Maintain safety • Increase plant performance • Increase generation capacity • Improve availability and reliability • Improve operation and maneuverability • Reduce O&M costs IAEA TWG-NPPIC Meeting

8. Preparation of a ten-yearly outage • The engineering team's basic questions • For the system X, is the "y" ten-yearly outage an ageing limit and the renewal an obligation? • Or with which maintenance conditions is it possible to reach the "y+1" ten-yearly outage? • If the renewal is an obligation, which technological solutions, or amplitude of refurbishment is needed? • To answer these questions a project with two phases is started • Equipment ageing observation phase • Studies to identify the possible scenarios for renovation • Preparation of a global action plan 5 years before outage IAEA TWG-NPPIC Meeting

9. The I&C Ageing Observation phase • Operating experience • Failure rate of modules • Maintenance costs • Generation losses due to equipment • Significant safety incidents and safety-relate events • Visual equipment inspection on-site • Identification of spare parts inventories • Number and sensibility to obsolescence's • Anticipation's study of identified ageing problems • Industrial support of the manufacturer • Study of operating environment of control equipment (ventilation, power supply, cables etc.) • Evaluation of the available margins IAEA TWG-NPPIC Meeting

10. 1300 N4 EPR 900 REC 70 Digital eq. (MicroRec) Digital equipment. (MicroRec) Electronic components (REC 70) Digital equipment (P320) Turbine Control Analog electronic components(8720 & 9020 series) DCS (Contronic E) Specific PLC (SCAP) DCS (T2000) 9020 series COTS DCS (Micro Z) Analog Automation DCS (Contronic E) Specific 1E PLC (CS3) DCS (T2000) Logic Automation Electromagnetic relays COTS PLC (Controbloc) Electromagn. Relays Analog electronic components Specific 1E digital system (SPIN) Specific 1E digital system (SPIN-N4) Specific F1A digital system (TXS) Reactor Protection Computerized CR Conventional panels (Remote & back-up) Computerized CR Conventional panels (Back-up. ) Control Room Systems Conventional panel Computerized aids Conventional panel Computerized aids I&C Technologies in the NPPs in France • Global initial strategy regarding “critical” I&C systems: • Spare part of components • Long term agreement with the suppliers : competencies and tools IAEA TWG-NPPIC Meeting

11. 900 MW : Rod Control system Modernization • Partial modernization (obsolescence and reliability issues) : Change the automation part (small analog/discrete modules). Keep the instrumentation (1E) and the power modules (gripper coil current generator). • New I&C System : • Computation • (Non-1E system) : COTS • PLCs • networks • Supervisor • Slave cycler • Time constraints (1ms) • FPGA-based modules • Site validation in progress (Tricastin) IAEA TWG-NPPIC Meeting

12. 1300 MW : Reactor Protection, Rod Control & Nuclear Instrumentation Systems • Context : • Increase in Performance : more sensors, more computation power… • Some aging & EMI problems • Modernization studies for the 3 systems on progress: • RPS : • Partial modernization at modules level : • « Clone of MC 6800 » and increase in clock rate • New FPGA-based modules with functions implemented in VHDL • Partial modernization at computation level with a (1E) COTS : keep the global architecture, the I/0 racks and the cabling • RCS : • Total modernization : a new I&C Systems • NIS: • Partial modernization at modules level • Partial modernization at computation level : keep the I/0 racks and cabling IAEA TWG-NPPIC Meeting

13. 1300 MW : Logic Automation - Controbloc • Context : • New functionalities may be added, but not enough margin • No problem (aging, obsolescence…) for the next ten years • Some improvement at the system level can be considered (reliability…) • Studies in progress • Addition of new I&C systems (PLCs): • Connection to the existing (proprietary) Controbloc : development of a “bridge” • interface between the existing CAD tool and the CAD tool of the new PLC • Anticipation of a possible modernization at the next ten-yearly outage (at the interface/connector level) • Re-design of some modules (FPGA-based solution to be considered) • Development of a validation tool for logic application, with a high coverage rate IAEA TWG-NPPIC Meeting

14. 1300 MW : Analog Automation • Turbine control system • µREC : Obsolescence, modification for power generation improvement • Renovation of the system • REC 70 : Long term agreement OK, modification for power generation uprate • Choice between modification/renovation • General Control system : • 9020 : long term agreement OK, functional improvement • Modification may need to change the system • µZ : long term agreement OK, functional improvement • Modification of the application only IAEA TWG-NPPIC Meeting

15. Control Room modernization – Enhancement of the exploitation • 1300 MW Control Room Modernization • Supervision : new supervisor, improvement of the alarm management… • Monitoring : digital recorders, Core 3D_monitoring… • Human factor impact • INTEP Projects : modern Information Technologies Integration • EPO project : Smart applications to support operation and diagnosis • E.g. : use of wireless sensors for monitoring activities (e.g. : vibration data collection) • TELL Me project : Smart help for field operations • E.g. : tagging-out and lining-up for outage • R&D-A Project : New solutions for outage management and maintenance/logistics preparation • E.g. audio& video monitoring, shared real time information (dashboards) IAEA TWG-NPPIC Meeting

16. Studies Focusing on FPGA Technology • Context : • Microprocessor-based system are more & more complex : no more dedicated to industrial domains  Needs for suitable I&C products • FPGA (or ASIC) might be a cheaper, simpler solution than PLC (µProcessor)-based solutions • For new products as well as for replacing specific components/modules of I&C systems • IEC 62566 : a new standard for Complex Electronic Components (incl. FPGA) • Available in 2011 • R&D studies, in the IEC 62566 context : • Cloning a component : « 6800 IP » suitable for 1E application • « FPGA-based » modules  Develop a method for the qualification of FPGA-Based technology IAEA TWG-NPPIC Meeting

17. Recommendationsto IAEA Items to be considered

18. Items to be considered for Maintaining the current I&C Systems • Obsolescence and Ageing of I&C equipment (analog equipment, digital equipment, cabling, connectors…) • Management of spares, long-term storage, verification • Approaches to facilitate replacement : E.g., portability of applications on “easily” replaceable platforms • Understanding of ageing mechanisms and factors, in particular for current integrated circuits and electronic boards • Estimation / Extension of remaining lifetime (obsolescence, aging mechanisms…) • Long-term management of I&C expertise • Ageing workforce, inadequate existing documentation, new digital technologies tend to become obsolete rapidly… • Identification and documentation of key knowledge, including I&C design basis • Means to retrieve, structure and use documented knowledge for new generation  Guidance for Maintening existing I&C Systems IAEA TWG-NPPIC Meeting

19. Safety Related Issues to be considered - 1 • Regulatory uncertainties regarding “new” technologies • ASICs / FPGAs : for replacement, for new I&C systems • Wireless technologies : May avoid / limit need for new cabling for additional monitoring measurements. Could be used to assist and integrate the work and actions of local teams • Data communication networks (including fieldbus) • Cyber-security  Guidance for a safe use of new technologies • Safety evaluation of COTS I&C equipment • I&C platforms, “smart” devices… (we are at the limits of the acceptable complexity) • What is common to, and can be shared by, all / most countries? • What can be shared with other safety-aware industries?  Common requirements and assessment criteria : international consensus to be reached (regulatory requirements) IAEA TWG-NPPIC Meeting

20. Safety Related Issues to be considered - 2 • Evaluation of the overall impact of I&C modernization on plant safety • New technologies may introduce new failure modes • The limits are nearly reached in term of complexity (architecture, components…) • Diversity may increase complexity • New technologies may also have beneficial effects • E.g., improved equipment reliability, improved fault tolerance • Representation of digital systems in probabilistic models • Realistic consideration for assessment of software (system + application) : Verification and Validation (tests) as complementary tools • Realistic consideration of software common cause failures IAEA TWG-NPPIC Meeting

21. Items regarding Improvement of Plant Performance (1) • Power uprate • New technologies for reduction of uncertainties in measurements to increase power output while maintaining safety margins • Improved plant availability • I&C equipment critical to plant availability • Identification • Dependability assessment • Evaluation of effects on plant availability • Reduction of likelihood of human errors • Improved fault tolerance • Improved actuator lifetimes • Improved diagnostics IAEA TWG-NPPIC Meeting

22. Items regarding Improvement of Plant Performance (2) • Improved equipment reliability • Identification of wear & ageing mechanisms, and of I&C contribution • Predictive, condition-based equipment maintenance, early fault detection • Practical operation & maintenance decision aids from raw information • Additional information for improved equipment reliability • Improvement of thermal efficiency • Detection of thermal losses • Reduction of operation & maintenance costs • Fleet monitoring, remote access to information by centralized experts • Information System, aids aimed at each local Operation Branch (Control, Maintenance, etc) • Homogeneous control room systems IAEA TWG-NPPIC Meeting

23. Optimization of Costs and Uncertainties of I&C Projects • Guidance for good utility requirements • Guidance for analogue - digital transition • Guidance to minimise costs and uncertainties of I&C modernisation projects • Guidance for evaluation of costs, risks, benefits of different I&C modernization options • Including maintenance of statu-quo • Over the remaining lifetime of the plant • Consideration also of capital budget and license renewal constraints IAEA TWG-NPPIC Meeting