New Build Simulators - L-3 MAPPS - L

A semi-annual report on L-3 MAPPS
Power Systems and Simulation activities
CPR1000
New Build Simulators
Issue 33 | July 2011
deployed at Hongyanhe Site
Page 6
IN THIS ISSUE
VIEW POINT....................................................................2
Milt Caplan talks about Fukushima
COMPANY NEWS...........................................................3
Michael Reed joins L-3 M&PS
NEW BUSINESS.............................................................4
Embalse DCC refurbishment
Callaway AEPS models
SPECIAL REPORT...........................................................6
Hongyanhe Simulators in service
Ling Ao Phase II Simulator PAC
CUSTOMER PROFILE....................................................8
Eletrobras Eletronuclear’s Ilson Soares
PROJECT HIGHLIGHTS............................................... 10
PROJECT PERSPECTIVE............................................. 12
Greg Zakaib discusses teamwork
TECHNICAL DEVELOPMENTS.................................... 14
Orchid® Touch Interface
INFO EXCHANGE......................................................... 16
2011 Owners Circle™ Conference (Tampa)
Recent Events
Upcoming Events
LIGHTER SIDE............................................................. 19
viewpoint
Fukushima
Why are we hanging our heads so low?
On 11 March 2011, Japan was hit by 9.0 earthquake and subsequent tsunami. The Fukushima Dai-ichi nuclear complex suffered major
damage and is not expected to reopen. The earthquake and tsunami disabled the reactor cooling systems, leading to nuclear radiation
leaks and triggering local evacuation. There has been much press coverage on this topic – some useful and based on science, some plain
non-factual nonsense. Being a key simulation technology supplier for nuclear plants all over the world and a provider of plant computer
system hardware for CANDU plants, L-3 MAPPS is of course always monitoring the media and seeking lessons learned from the events
that unfolded at Fukushima Dai-ichi. For this issue of simnews, we invited Milt Caplan of MZConsulting Inc. to share his views with us.
It has now been about four months since the horrific earthquake and
tsunami that caused the damage at the Fukushima Dai-ichi Nuclear
Power Plant. The people of Japan continue to suffer from this mindboggling natural disaster with the death toll at well over 20,000. And
yet when we hear about Japan on the news it is the accident at the
nuclear power plant that dominates the headlines.
state and some radiation continues to be released, although progress
is being made.
Now let’s look at the consequences of this disaster. First and
foremost, there have been no fatalities due to radiation; there has
been no exposure to the public that exceeded allowable limits, while
six workers have received doses higher than their already increased
The world has reacted. Countries like Germany are moving to abandon allowable limits. And while the evacuation zone is still in place and
nuclear power in the disaster’s wake, Switzerland has followed and will be for some time, at this point it seems likely that there will be
Italy has stopped its movement away from a moratorium. In most no long-term contamination requiring moving people away from their
other countries there is continued support for nuclear power, although home permanently.
there is a definite pause in new build as the lessons are learned and
That being said, I think we should all take a moment and be proud of
safety is re-evaluated.
our industry, proud that in the worst accident in 25 years, there are
Within the nuclear industry there are many who are crushed by this no immediate and no expected longer-term radiation fatalities. And
event; in fact no one is more disappointed and concerned about that is what nuclear safety is all about.
Fukushima than the industry itself. We have this tremendous ability
So when we say we can we do better, what do we mean? We can’t
for self-criticism. We believe we need to suffer because of this, and
have less than zero fatalities or less than zero excessive exposures.
we know for certain that we need to do better. The IAEA is looking into
Going back to the requirements, I would say the two real issues
how to improve safety at nuclear plants, and I have seen numerous
needing improvement are the fact that there were releases, likely
write-ups suggesting a number of preliminary lessons learned. Some
due to cracking in the containment structures – and this should not
include placing backup generators at a higher level; others are
happen; and of most importance, the time to get the fuel cooling
looking at having a strategic power supply available for delivery to
systems functioning and removing all of the decay
site within a short time frame after an accident as
heat is excessive. The fear caused to the public
needed. Many of these ideas are quite good, and
and the subsequent reaction of governments may
I expect that the best of these will ultimately be
be the largest lasting impact. We need to set more
implemented. In fact there has already been an
strict guidelines for how to do better here and focus
IAEA sponsored ministerial conference on nuclear
on reducing the time to cold shutdown following
safety held as a direct result of this event.
such extreme events. I am sure we can think of
As engineers, we have a tendency to jump to
many other improvements in terms of reduced
solutions before we have the problem well defined.
consequences, and that should be a matter for
Almost every day, I hear people within the industry
further discussion before talking about fixes. It is
and elsewhere stating that “we need to improve
interesting to see the IAEA revising their charting
safety.” However, what I do not see is anyone
system for this event to focus on three items: risk
clearly articulating what we mean by that. Let’s
of criticality, long-term decay heat removal and
discuss and identify the requirements of such a
mitigation of radioactive releases.
statement. Defining “improved safety” is the first
Now while it is also useful to look at the many
critical step. Many of the suggestions so far will
potential improvements to the plant designs to
help with the next earthquake and tsunami, but
reduce the likelihood of such an accident, it would
what about other unexpected events?
be imprudent to assume that some other event
So let’s go back to the beginning. We had an extreme natural disaster that we haven’t contemplated would never happen. Hence one of
that was well beyond what was expected for this plant. At first the the biggest lessons learned is that low-probability events can indeed
plant performed as designed, but the tsunami was too much and happen. And this means we need to review and see how to potentially
many things went wrong. The natural disaster affected multiple units make improvements in severe accident management.
at the site and strained the ability of the workers to meet the needs
But overall, I am hoping that at some point this event will be seen to
of the plant to the extreme. Backup power was lost for weeks, not an
have had a number of positives. I can’t think of any other industry
assumption in the analysis. I’m sure that there will be many, many
where the worst event in decades is one that results in no deaths.
other things that went wrong once the accident is studied in detail.
This is because this is what we expect of ourselves. Other energy
And most of all, the plants are yet to be placed in a safe cold shutdown
2 | simnews | Issue 33
Summary of severe (≥ 5 fatalities) accidents that occurred in fossil,
hydro and nuclear energy chains in the period 1969-2000
OECD
Energy chain
Non-OECD
Accidents
Fatalities
Fatalities/
GWey
Accidents
75
2,259
0.157
Fatalities
Fatalities/
GWey
18,017
0.597
819
11,334
6.169
Coal (without
China)
102
4,831
0.597
Coal
Oil
165
3,713
0.132
232
16,505
0.897
Natural Gas
90
1,043
0.085
45
1,000
0.111
LPG
59
1,905
1.957
46
2,016
14.896
Hydro
1
14
0.003
10
29,924
10.285
Nuclear
0
0
---
1
31*
0.048
So as I see it there are two
outcomes from an event such
as this one. First, as we would
all expect, we will have many
lessons learned so that we can
make improvements in nuclear
plant operation and safety. And
that is great as we all strive for
continuous improvement in
safety in this industry.
viewpoint
1,044
Coal (data for
China 19941999)
and a long-lasting impact on
the people of Northern Japan.
But of equal or even more
importance, perhaps this event
will also demonstrate that even
Total
390
8,934
1,480
72,324
in what are perceived as very
*Note: These are immediate fatalities only.
bad nuclear accidents, the
Source: Comparing Nuclear Accident Risks with those of other Sources – NEA 2010
consequences have a minimal
effect on population health. If
industries don’t ever think this way. Accidents resulting in deaths are we explain things correctly, we can demonstrate that even when these
commonplace and readily accepted.
accidents happen (and I hope we have also learned that accidents do
This can be clearly seen in the above chart. Or as stated by Stewart indeed happen), we can have confidence in their outcomes, and thus
Brand in his book Whole Earth Discipline, “Radiation from nuclear build confidence in the public that global catastrophe is not around
energy has killed not a single American, but of all these energy by- the corner as a result of nuclear power and that indeed the industry
products, it is the only one we dread.” Or look at the German example. is what we want it to be – SAFE.
An accident in Japan that is of no direct consequence to Germany (no
tsunamis on the Rhine!) has resulted in a dramatic decision to stop
its nuclear power program. Yet disease coming from an organic farm
Milt Caplan, President of MZConsulting Inc., has 30 years’
has killed many in Europe and there is no call to eliminate organic
experience in the nuclear industry advising utilities, governments
farming or call international ministerial conferences on organic food
and companies on new build nuclear projects and investments in
safety. This is just the world that we live in.
uranium. He is the current chair of the World Nuclear Association
So why are we all hanging our heads so low feeling that we have
Economics Working Group and is on the faculty of the World
failed? A 40-year-old plant has survived a once-in-a-lifetime natural
Nuclear University where he teaches nuclear economics and
disaster. The consequences to the public have been modest, mostly
nuclear plant structuring and financing. Milt obtained his
inconvenience and fear, but no injuries or deaths, while the natural
Bachelor of Engineering in Nuclear Engineering from Rensselaer
disaster that caused it has resulted in tens of thousands of deaths
Polytechnic Institute in Troy, New York, USA, and an MBA from the
University of Toronto.
L-3 MAPPS now part of
Controls & Integrated Systems Sector
Mike’s office will be in L-3’s Poway, CA facility. Reporting to Mike will be Don
Roussinos, president of L-3 Maritime Systems, Peter Dawson, president of
L-3 MAPPS and Tony Gardiner, vice president and general manager of L-3
Dynamic Positioning & Control Systems. L-3 Westwood, New Orleans will
continue to report to Jerry Ozovek, president of the Power Systems Sector
until further notice.
Prior to joining L-3, Mike was with General Atomics serving as senior vice
president, Survivability Group. Prior positions included president & CEO
of their Electronics Systems Company and senior vice president for the
Advanced Technologies Group. Prior to joining General Atomics in 1997,
he completed 22 years of naval service as an engineering duty officer
having achieved the rank of Captain. His active duty assignments included
sea duty on USS Saratoga, tours at the Naval Sea Systems Command, the
Board of Inspection and Survey and Supervisor of Shipbuilding in Bath,
ME and Pascagoula, MS. He was director of design for the Navy’s DDG51 Class Aegis Destroyer Program and Navy Program Manager for their
Advanced Electric Technology Program Office. Significant programs under
his development at General Atomics include Electromagnetic Aircraft
Launch System (EMALS) and Advanced Arresting Gear (AAG) for the CVN78 FORD Class aircraft carrier.
He holds both an Ocean Engineer advanced degree and a Master’s degree
in Naval Architecture and Marine Engineering from the Massachusetts
Institute of Technology and a Bachelor’s degree in Electrical Engineering
from Iowa State University.
July 2011 | simnews | 3
companynews
At the end of June 2011, L-3
Marine & Power Systems (M&PS)
Group was reorganized into
functional areas or sectors. The
Group president, Robert Leskow,
announced the formation of the
Controls & Integrated Systems
Sector. This new sector within
M&PS is comprised of L-3
Maritime Systems (Leesburg,
VA and Newburyport, MA), L-3
MAPPS (Canada, UK and India),
L-3 Westwood (New Orleans,
LA) and L-3 Dynamic Positioning
& Control Systems (Poway,
CA). The Controls & Integrated
Systems Sector will align these
Michael R. Reed,
business entities to leverage
President, Controls & Integrated
Systems Sector
core competencies, maximize
efficiencies and improve products
and services to better support our customers and provide opportunities
for revenue growth.
Michael R. Reed has been appointed to the role of president of the
Controls & Integrated Systems Sector, reporting directly to Robert Leskow.
newbusiness
L-3 MAPPS to Add Value to
Embalse Refurbishment
with Digital Control Computer Systems
L-3 MAPPS has been awarded a contract from Nucleoeléctrica
Argentina S.A. (NA-SA) to replace the Embalse nuclear power
plant’s Digital Control Computer (DCC) systems hardware. Four
DCC systems will be delivered to NA-SA under the contract. The
first system will be used as a testing and training platform and
is due to be installed in early 2013. Three other redundant DCC
systems for plant operations are expected to enter service in mid2014. The project design process is currently underway.
DCC systems are used to monitor and control the major reactor and
power plant functions at CANDU* nuclear power plants. The new
DCC systems will feature the latest SSCI-890 CPUs and modern VMEbased replacements for the existing Ramtek display system, and will
replace the Varian 73 computer systems and related equipment.
“L-3 MAPPS is committed to working with NA-SA on the Embalse
plant,” said Michael Chatlani, vice president of marketing & sales for
L-3 MAPPS Power Systems and Simulation. “Along with the full-scope
simulator we are currently developing, the replacement DCC systems
will help improve plant operations.”
“In support of the Embalse plant refurbishment project, NA-SA
is pleased to work with knowledgeable industry partners like L-3
MAPPS,” said Rubén Semmoloni, Embalse nuclear power plant lifeextension project director, NA-SA.
4 | simnews | Issue 33
The Embalse nuclear power station is one of two operational nuclear
power plants in Argentina. It is located on the southern shore of a
reservoir on the Rio Tercero, near the city of Embalse in Córdoba
Province, 110 kilometers southwest of Córdoba City. The single unit
at Embalse is a CANDU pressurized heavy water reactor with a net
output of 600 MWe, which went into commercial operation on January
20, 1984. Embalse also produces the cobalt-60 radioisotope, which
is used for medical and industrial applications. With the current plant
refurbishment plans, the station’s life is expected to be extended for
another 25 years.
* CANDU is an acronym for CANada Deuterium Uranium and is a
registered trademark of Atomic Energy of Canada Ltd. The CANDU
system is a design that uses deuterium oxide (heavy water) as the
moderator and coolant, and natural uranium as fuel.
newbusiness
Alternate Emergency Power System work at
Callaway
L-3 MAPPS has earned follow-on orders from Ameren Missouri to
upgrade the full scope simulator for the Callaway Energy Center
in Callaway County, Missouri, USA. One order will provide for
the addition of an alternate emergency power system (AEPS)
model, and in the other order L-3 MAPPS will modify the interface
between its Orchid® Core Builder and the fuel analysis code used
to perform the actual nuclear power plant fuel cycle updates. The
AEPS model upgrade is scheduled to be completed in four months,
and the fuel data input model will be updated in the fourth quarter
of 2011.
The interface between Orchid Core Builder and the data generated
by the fuel analysis code will also be updated as the Callaway Energy
Center transitions from CASMO4/SIMULATE3 to Westinghouse’s
PHOENIX-P/ANC.
“Since our first order for upgrading the Callaway simulator in 1997,
the simulator has been progressively upgraded by L-3 MAPPS to
the point where the legacy simulator has in effect been replaced
and is entirely functioning in L-3 MAPPS’ industry-leading Orchid
environment,” said Michael Chatlani, vice president of marketing &
sales for L-3 MAPPS Power Systems and Simulation. “Thanks to the
The AEPS added to the station includes four 2-megawatt diesel performance gained with L-3 MAPPS models, the robust simulation
generators located 1.5 miles off-site to improve Callaway’s ability technology and our committed service, we continue to secure addto mitigate a station blackout. The AEPS generators provide an ons and we greatly value Ameren Missouri’s business.”
alternate source of power during a station blackout that is different
from the emergency diesel generators and off-site resources. The Ameren Missouri has been providing electric and gas service for more
off-site diesel back-up systems start up when there is a loss of than a century, serving 1.2 million electric and 126,000 natural gas
both safety-related emergency diesel generators and a loss of off- customers in central and eastern Missouri. The company’s service
site power. As an enhancement to the simulator, L-3 MAPPS will area covers 63 counties and 500 towns, including the greater St.
model the AEPS generators associated switchgear, transformers Louis area. Since 1984, the Callaway plant has been providing safe,
and connection to the Central Electric Power Cooperative, all with clean and affordable electricity. The electricity generated by the
L-3 MAPPS’ Orchid Modeling Environment. Invensys’ Wonderware Callaway plant is enough to meet the needs of 780,000 average
InTouch human-system interface for the AEPS will be emulated with households every year.
L-3 MAPPS’ Orchid Control System.
Callaway Unit 1 Quick Facts
Utility: AmerenUE
Reactor Supplier:
Westinghouse
Reactor Type:
PWR
Capacity:
1,190 MWe (net)
Date of Operation:
December 1984
Location:
Fulton, Missouri, USA
July 2011 | simnews | 5
specialreport
L-3 MAPPS Deploys
Simulators for the
CPR1000 New Build
Hongyanhe Site
A second pair of L-3 MAPPS-developed simulators for the
CPR1000 nuclear plant design have entered service at the
Hongyanhe Nuclear Power Training Center. The first simulator,
which was developed for units 3 and 4, was handed over to
Liaoning Hongyanhe Nuclear Power Co. (LHNP) in November
2010, and the second, for units 1 and 2, in March 2011. After
extensive testing, the simulators were deployed to allow operator
training to proceed. Several updates to the simulators are still
to follow as updated digital control system (DCS) information is
made available to L-3 MAPPS.
The simulators support all major training requirements and are
available for LHNP to prepare operators well before first fuel loading
of Hongyanhe unit 1, which is targeted for early 2012. The simulators
have been tested for normal operations – from cold shutdown to
100 percent full power and from 100 percent full power to hot,
intermediate and cold shutdown, as well as for mid-loop operations
and core performance. In addition, numerous transient tests have
been successfully demonstrated, including loss of coolant accidents,
steam line breaks, loss of feedwater, reactor and turbine trips, load
rejections, steam generator tube ruptures, and more.
The deployment of the Hongyanhe Phase I simulators follows the
delivery of a series of high-performance, reliable simulators provided
by L-3 MAPPS and its partners for China Guangdong Nuclear Power
Company’s (CGNPC) Daya Bay, Ling Ao and Ling Ao Phase II sites. The
first three full-scope simulators are being used for operator training
six shifts per day with an availability of 99.8 percent (of uptime).
The simulation technology has also been used for other applications,
including technical support for the operating plants and emergency
planning, among others.
The Hongyanhe project is the first to be built in northeast China as
part of the country’s plans to upgrade its aging industrial base and
will be operated by LHNP. The new Hongyanhe Nuclear Power Plant
site, located in Hongyanhe Town of Wafangdian, 104 km north of
Dalian City in Liaoning Province, will have six generating units, each
featuring China’s standard CPR1000 design, and a 1,080-megawatt
three-loop Pressurized Water Reactor (PWR) whose design is
being coordinated by China Nuclear Power Engineering Company.
The Hongyanhe plant units are the first in a series of CPR1000
units that utilize Mitsubishi Electric’s MELTAC safety digital control
“The successfully launched Hongyanhe simulators are the latest
system (DCS) and the CTEC-supplied HOLLiAS non-safety DCS. The
examples of L-3’s progressive simulation technology and techniques,”
Hongyanhe plant serves as a reference for other plants already under
said Michael Chatlani, vice president of marketing & sales for L-3
construction, namely the Ningde, Yangjiang and Fangchenggang
MAPPS Power Systems and Simulation. “We stand ready to support
Nuclear Power Stations.
the continued growth and success of the Chinese nuclear power
industry with our state-of-the-art simulation solutions for operational Liaoning Hongyanhe Nuclear Power Company is a joint venture
excellence and safety.”
between China Guangdong Nuclear Power Co. (CGNPC), China Power
Investment Corporation (CPIC) and Dalian Construction Investment
The Hongyanhe simulators take advantage of process models
Group. CGNPC is responsible for project construction and the
developed and maintained within L-3 MAPPS’ Orchid® simulation
first five years of commercial operation of the plant with full-scale
environment. The plant’s non-safety control sequences, developed
participation by CPIC.
by China Techenergy Co. (CTEC), have been translated by L-3 MAPPS
and are also available in Orchid for quick modification, visualization
and validation of the control design by LHNP.
6 | simnews | Issue 33
Milestone on
Ling Ao Phase II Simulator Project
witnessed in January 2010 by China’s nuclear regulatory authority, the
National Nuclear Safety Administration. Unit 1 of the Ling Ao Phase II
complex entered commercial operation in September 2010 and Unit 2
is planned for August 2011.
To achieve PAC, the simulator was updated to account for all plant
changes since the August 2009 simulator delivery, including commercial
operation results. A simulator availability test was performed, which
demonstrated a simulator availability of 99.42 percent. With this
milestone achieved, the simulator’s warranty period is now underway.
“With the plant and digital control systems (DCS) designs being firmed
up in parallel with the simulator’s development, the supplier and
customer teams faced tremendous hurdles to complete this project,”
said Peter Dawson, president of L-3 MAPPS. “We are extremely proud
of what the team has accomplished on the Ling Ao Phase II program
and are grateful to so many contributors, including representatives from
DNMC, CNPEC, AREVA and Siemens for their outstanding collaboration.”
Seated from left to right: Doris Kittelmann (Siemens), Jean-Paul Mauduit
(AREVA) and Zhang Ruiqiong (CNPEC). Standing from left to right: Ma
Deyou (DNMC), Frederic Personeni (AREVA), Li Jinguang (DNMC) and
Gregory Zakaib (L-3 MAPPS).
The Ling Ao Phase II nuclear power plant full scope simulator (FSS),
the first-ever simulator for a CPR1000 plant, has attained another
significant milestone. In a ceremony held in Paris on 28 June 2011
marking the issuance of the provisional acceptance certificate
(PAC), L-3 MAPPS joined AREVA, Siemens, Daya Bay Nuclear
Power Operations and Management Company (DNMC) and China
Nuclear Power Engineering Company (CNPEC) to formally hand over
the simulator to DNMC on behalf of the Ling Dong Nuclear Power
Company.
In cooperation with AREVA and Siemens, L-3 MAPPS successfully
delivered and installed the FSS in August 2009. The first plant license
operator examinations were successfully carried out on the FSS and
Integrated with AREVA- and Siemens-supplied DCSs, replica control
room panels, and a stimulated human-machine interface, the FSS
features L-3 MAPPS’ advanced instructor station capabilities and a
proven Windows-based graphical simulation environment. Advanced
plant models have been deployed and validated for the reactor,
thermal-hydraulic, balance of plant, electrical, and I&C for the turbine
control and other miscellaneous systems not controlled by the AREVA/
Siemens DCSs. The safety systems DCS is AREVA’s Teleperm XS, and
the operational I&C DCS system is Siemens’ SPPA-T2000 with OM690
human-machine interface.
The Ling Ao Phase II nuclear plant, owned by Ling Dong Nuclear Power
Company, comprises the first two CPR1000 generating units put
into service. The CPR1000 is a Chinese standard design featuring a
1,080-megawatt three-loop pressurized water reactor, whose design is
coordinated by CNPEC. Both the plant and the simulator are located in
Da Peng on the coast of Daya Bay in Guangdong Province, about 45 km
from the city centre of Shenzhen and about 50 km from Tsim Sha Tsui,
Hong Kong Special Administrative Region.
July 2011 | simnews | 7
specialreport
L-3 MAPPS Attains Major
customerprofile
Navigating
Simulator Challenges
with Eletrobras Eletronuclear’s Ilson Soares
In the summer of 2009, L-3 MAPPS commenced work on upgrading the Angra 2 full scope simulator (FSS) at the Almirante Álvaro
Alberto Nuclear Power Station for Brazil’s Eletrobras Eletronuclear (ELETRONUCLEAR). Angra 2 is a Siemens-designed pressurized
water reactor (PWR) with a net output of 1,350 MW that was connected to the grid in 2000. It is located near the town of Angra
dos Reis, roughly 200 km west of Rio de Janeiro. To get some additional insight and provide a snapshot of the progress made on
the simulator upgrade project, simnews speaks with Mr. Ilson Soares, ELETRONUCLEAR’s Head of Training/Simulators.
simnews: The original Angra 2 simulator has an interesting history. installation, tests, effective use for training and disassembling of the
The simulator was delivered by the original vendor —Thomson-CSF— equipment, took place between October 1982 and February 1985.
in 1982, but Angra unit 2 went into service in 2000. Please explain.
In March 1985 the simulator was transported to Brazil and installed at
I. Soares: Right after the Brazilian Government’s decision to start the ELETRONUCLEAR Training Center. It has performed an extensive
the construction of the Angra 2 nuclear power plant (NPP), training program for operators, technical managers, commissioning
ELETRONUCLEAR negotiated two separate contracts for the and licensing personnel from foreign nuclear power plants, as well
acquisition of its simulator: one with the reference plant as specialists for national and foreign organizations involved with
manufacturer (Siemens/KWU), for the supply of the simulator control several activities related to nuclear installations and also with the
room hardware, development and supply of the plant specifications, operation of conventional electric power plants.
training and qualification of performance of commissioning tests of
Through this program, the Advanced Training Center “CTAS” has
the simulator; and another one with a simulator manufacturer, for
been offering theoretical and practical training for personnel from
the supply of the remaining simulator hardware (computer system,
various organizations and NPPs in Germany, Spain, Switzerland, USA
interface, instructor system), integration of all hardware components
and Brazil since it began operations in September 1985.
and development of the simulation software.
simnews: Up until recently, the Angra 2 simulator was running on an
The simulator was built by Thomson-CSF (France) and Siemens/
ENCORE RSX-6841D computer system. What were the main drivers
KWU (Germany) between May 1978 and September 1982, at the
for ELETRONUCLEAR to proceed with the current simulator upgrade
Thomson-CSF facilities in Cergy-Pontoise, France.
project?
Due to the interruption of the Angra 2 NPP construction in the early
I. Soares: Actually, the original computer system was composed
1980s, and, consequently, the postponement of the operator training
of three GOULD/SEL 32/75 computers, one GOULD/SEL 32/77
for the plant, ELETRONUCLEAR decided to make an agreement with
computer and associated peripherals. These four computers ran in
Siemens/KWU, aiming to temporarily use the simulator in Germany.
a quadric-processor parallel system, with a shared memory system
The Simulator was then installed in Karlstein, Germany, and some
for common data interchange. This hardware configuration was later
of the revenue obtained through the training of the personnel of
changed to two GOULD/SEL 32/75 and two GOULD/SEL 32/77
German NPPs was transferred to ELETRONUCLEAR by Siemens/KWU.
machines, and subsequently, to three GOULD/ SEL 32/77 and one
The operation of the simulator in Germany, including the periods of
GOULD/SEL 32/75 configuration.
8 | simnews | Issue 33
customerprofile
Due to increasing hardware maintenance problems, mainly caused
by the lack of replacement parts for those computers in Brazil, and
the need for more computational power and larger main memory,
ELETRONUCLEAR decided to acquire a new computer system. In
early 1993, an ENCORE RSX-6841D computer system was acquired
from ENCORE Computer Corporation and adopted as the simulator
server in July 1993. This computer system was selected on the basis
of software/hardware compatibility with the previous system, in
order to significantly reduce the overall migration time. The choice
proved to be the right one, and the new system was successfully put
in operation in early 1995. Unfortunately, ENCORE computers were
discontinued that same year.
I. Soares: The Angra 2 simulator is quite old and all the major
problems are related with this—its age. Many solutions that were
used in the past, during its construction, are not available anymore.
I would say that our main challenges were the conversion of the
assembler codes to C language and the development of a new
I/O controller, to connect the new computer environment to the
simulator control room. For the second phase, the main challenge is
to perform the conversion from bit to byte, which requires a change
in the overall model structure.
simnews: ELETRONUCLEAR personnel from the simulator organization and from the training department spent considerable time at L-3
MAPPS’ Montreal facility exercising the upgraded simulator in recent
months. What was their impression of working with L-3 MAPPS personnel? What about their views on our fine city?
During all those years, we have been keeping this simulator working
with our internal software and hardware teams. In order to avoid
hardware maintenance problems, we recently decided to rehost this
I. Soares: The L-3 MAPPS personnel made a very good impression on
simulator once again, converting all its assembler codes and making
us. We were very well treated by everyone in the company, not only the
all models portable and replacing the instructor station and three
specific L-3 MAPPS team assigned to our project. The project team
main simulated systems.
managers follow the project development very closely; they try to
solve problems as soon as they arise. During the factory acceptance
simnews: Please describe the upgrade project for our readers.
tests we were very impressed by the commitment, good relationship
I. Soares: The first phase of the project was for L-3 MAPPS to rehost
and teamwork of the whole L-3 MAPPS team, in particular, by the
the simulator’s software to PC/Windows-based computers running
very hard work done by the factory team leader.
L-3 MAPPS’ modern Orchid® simulation environment with advanced
instructor station capabilities. The legacy models programmed in To complement the great working experience, Montreal is a very
assembly language were to be converted to C language. The aging nice city. It is relatively quiet, safe and very clean. The people on the
master I/O controller was also targeted for replacement with a new streets are also very kind.
master controller from L-3 MAPPS to establish I/O communications
simnews: What’s left to do to complete the second phase of the
with the hard panels.
Angra 2 simulator upgrade project?
In the second phase, the primary system models will be replaced
I. Soares: In order to complete the second phase, we must complete
with higher fidelity models. L-3 MAPPS will supply its advanced
the development and integration of new modules for the reactor
neutronics model generated by Orchid Core Builder to replace the
core, the reactor coolant system, the containment and ventilation
reactor core model and use Orchid Modeling Environment to provide
systems.
the nuclear steam supply system, containment and HVAC models.
Several legacy modules and input/output routines must be updated
simnews: What is the current status of the project?
to transform bit-wise variables to byte-wise variables. Modules that
I. Soares: The factory acceptance testing period for phase I was must be converted from bit to byte include several I&C modules,
completed successfully on 13 May 2011. The Phase I equipment was alarms, electrical breakers, sub-loop controllers, plant computer
then shipped to the Angra 2 site, installed, and verified in the middle signals and the input/output system modules.
of June 2011. The current in-field activities include the installation,
Of course, we will have another round of acceptance tests at L-3
testing and final integration of the replacement I/O controller. This will
MAPPS’ factory in Montreal and then on-site acceptances tests
then end with “whole simulator” (including the legacy I/O system with
where the upgraded models will be tested for the first time with the
the replacement I/O controller) site acceptance by ELETRONUCLEAR
full simulator control room.
and on-the-job training of the system. In addition, other in-field
activities include change request (CRs) clearance and acceptance simnews: L-3 MAPPS is proud to be involved with the modernization
of remaining Phase I CRs. At the same time, Phase II activities are of the Angra 2 simulator. Please provide any concluding remarks.
proceeding. The development of the models that were upgraded is
I. Soares: L-3 MAPPS employed its state-of-the-art instructor station
complete. The integration of these models into the simulator with
with advanced capabilities which will give the instructors better tools
the legacy systems is currently ongoing and is due to be completed
and greater capability to execute the various training programs. In
by the end of July 2011. The bit to byte-wise conversion is also being
addition, the conversion of the legacy assembler code and rehost
completed. Pre-factory acceptance for phase II is scheduled to start
to modern simulator servers will greatly improve the ease of
on 26 July 2011 and factory acceptance on September 20.
maintenance of the simulator. Finally, with the upgrade of the reactor
simnews: What have been the major challenges in implementing core, NSSS, containment and HVAC models, this will significantly
this project so far?
expand the training capability of the simulator training scenarios and
improve its fidelity.
July 2011 | simnews | 9
projectperspective
Real Teamwork
The Key to Success in China
Gregory Zakaib, L-3 MAPPS program manager, shares his
perspective on two important projects that L-3 MAPPS took on in
China recently.
L-3 MAPPS has been in the power plant simulation business for
almost 40 years. The experience gained as world leader in power
plant simulation was essential to our recent work in China to develop
the first full scope simulators (FSS) for their new build: first for Ling
Ao Phase II nuclear power plant (NPP) in Guangdong Province and
then for Hongyanhe Phase I NPP in Liaoning Province.
In 2005, L-3 MAPPS was tasked with building the Ling Ao Phase II
FSS using AREVA and Siemens digital control systems (DCS). Then
in 2007, L-3 MAPPS was entrusted with developing a second pair
of FSSs for the Hongyanhe NPP, the reference plant for follow-on
CPR1000 projects under construction using DCSs from Mitsubishi
Electric Corp. (MELCO) and China Techenergy Co. (CTEC).
Both Ling Ao Phase II and Hongyanhe Phase I simulators support all
training requirements and were available to prepare operators well
before first fuel loading.
Although the main purpose of the FSS projects was to develop
training devices, throughout their implementation both simulators
contributed to the deployment of the NPP’s DCSs by acting as “live”
plant.
L-3 MAPPS is not new to China. For over a
decade, a series of high-performance, reliable
simulators were delivered to China National
Nuclear Corporation for the Qinshan Phase III
plant and to China Guangdong Nuclear Power
Company’s (CGNPC) Daya Bay and Ling Ao (Phase
I) plants.
The full scope simulators at Daya Bay and Ling
Ao are being used for operator training six shifts
per day at an availability of 99.8 percent (of
uptime). The simulation technology has also been
used for other applications, including technical
support for the operating plants and emergency
planning, among others.
The projects required the integration of several technologies and
deliverables from different vendors. It was a challenge for the
teams – located all over the globe and spanning multiple cultural
backgrounds – to collaborate, share knowledge and share work.
Ling Ao Phase II FSS Project Leaders. From left to right: Qin Dexin
(CNPEC), Ma Deyou (DNMC), Li Jinguang (DNMC), Doris Kittelmann
(Siemens), Luigi Vindigni (L-3 MAPPS), Frederic Personeni (AREVA),
Gregory Zakaib (L-3 MAPPS) , Sieghard Ewert (Siemens).
Ling Ao Phase II FSS team during system integration in Montreal
LHNP, CNPEC, MELCO, CTEC and L-3 MAPPS gather in 2009 for an
Hongyanhe Phase I FSS project meeting in Montreal
12 | simnews | Issue 33
projectperspective
Hongyanhe Phase I FSS contract signing ceremony with MELCO
in Hong Kong (July 2007)
2009 Christmas dinner in Shenzhen hosted by L-3 MAPPS with friends
from AREVA, Siemens, CNPEC and DNMC
With the involvement of over 30 L-3 MAPPS engineers and 10 local
subcontractor personnel, the project successes were rooted not
only in the basic teamwork concept of cooperation, but also in the
participants’ eagerness to learn something new – both technically as
well as culturally – from their colleagues.
Short and long-term expatriation benefits the individual in a variety
of ways: skill transfer, managerial control and personal development.
Even a short-term relocation provides invaluable experience, as often
the only way to understand another business culture is to become
immersed in it, particularly in growing economies such as China.
In an era of videoconferencing and virtual meetings, distance is no
longer a barrier to doing business. But succeeding internationally
means more than just getting hold of people overseas. One must
have a global mindset – a blend of experience, attitude and
understanding of other cultures. The many projects L-3 MAPPS has
delivered over the years and its experiences dealing with different
cultures prepared us well for the challenges that lay ahead.
When relationships between team members are built and confirmed
on an ongoing basis, a culture of trust develops even when members
are working away from one another. The way a group behaves and
performs affects each of the individual members. When trust is
present and group behavior is positive, each team member’s positive
experience in turn leads to greater trust and ongoing participation.
Because of the unique challenges confronting the CPR1000 teams
which were not co-located, it was important to establish a strong
foundation at the beginning of the projects to ensure that teams
worked toward the same goals to ensure success.
Extra efforts were needed to exploit the benefits of global teams
while minimizing the disadvantages that arise from communication
difficulties and a lack of physical contact. This was done by forging
strong relationships between teams, building trust, celebrating
rewarding experiences and having team members spend as much
face time together as possible.
The FSS projects presented an opportunity not only to integrate
technologies, but to offer each team member the chance to travel and
perform long-term localized assignments. Expatriate assignments
Mongolian hut dinner in Beijing (July 2010): a great time for the L-3
were employed by all parties in various phases of the projects.
MAPPS and MELCO teams
Coming together is a beginning
Keeping together is progress
Working together is success
- Henry Ford
Hosting customers in workshops in Montreal during integration
phases and scheduling team outings and events at the various sites
often allowed the team members from each company to bond while
learning about the local cultures.
The successes of the CPR1000 FSS projects were a product not
only of proven technology and technical know-how, but also of the
triumphs and experiences gained by the team members.
July 2011 | simnews | 13
technicaldevelopments
Orchid® Touch Interface
launched
Earlier this year, L-3 MAPPS introduced Orchid® Touch Interface, an enhanced graphical user interface aimed at elevating our
customers’ classroom training experience and at reducing the time demands on their full scope simulators. The first time that Orchid
Touch Interface was demonstrated in a public forum was at the Utilities Service Alliance’s 2011 USA Nuclear Generator and Supplier
Executive Summit which took place in Grapevine, Texas from 14 to 17 June 2011. The response to the new product was immensely
positive.
Offloading your full scope simulator with minimal USER INTERFACE
investment
Orchid® Touch Interface’s touch screen interface allows students to
Is your full scope simulator in use around the clock? Do you have
numerous young learners who have grown up in the electronic age
and are more comfortable with interactive technology? Due to the
high fidelity of your L-3 MAPPS simulation models, are there other
“beyond training” demands on your full scope simulator (engineering
support, exam development, pre-operation plant upgrade
verification)?
operate the panel graphics manually and obtain life-like visual and
audible real-time responses.
To keep training as realistic as possible, the popular panning and
zooming of the soft panels in the instructor station are disabled for
Orchid® Touch Interface, providing individual students and teams
the opportunity to know the actual location and orientation of panel
devices that are vital to operating your plant. Navigation can be
L-3 MAPPS simulator users have already invested in their high fidelity performed from one panel to another without the risk of having an
simulators with virtual panels which run on the instructor station and unrealistic layout of panel devices. which are also available in student mode. So, the answer to these In an environment where all panels are not visible at the same time,
questions is to offload the demands on your full scope simulator off-view annunciators can be missed, creating a gap in training. With
by reusing the exact simulation software and virtual panels with Orchid® Touch Interface, any time an off-screen alarm actuates
Orchid Touch Interface without a significant investment. With new (annunciators located on panels in an area that the learner is not
and improved large touch screen technology, L-3 MAPPS now brings presently looking at), an indicator appears to warn the student. With
classroom training to another level with Orchid Touch Interface.
a simple touch of that same indicator, an overview of the control
room is displayed, indicating which panel is in alarm. From that same
interface, the student can then navigate to it quickly.
Ray shows off Orchid® Touch Interface
14 | simnews | Issue 33
technicaldevelopments
ADVANTAGES
•F
ull-scale control room training environment at a fraction of the
cost of your full scope simulator, capitalizing on the investment
you have already made.
• L ife-like training environment to augment your current full scope
simulator environment, for both individual and team training.
•O
ffload your full scope simulator by using a device that fits the
needs of young learners.
• L -3 MAPPS’ client-server architecture guarantees realistic response
times for all virtual panels, whether the simulated plant is in
normal conditions or a severe transient is being experienced.
• T ake full advantage of the powerful instructor station capabilities
you already have through Orchid® Instructor Station with Orchid
Touch Interface.
•U
se one bay of large touch screen monitors or reproduce the entire
control room with multiple monitor bays.
July 2011 | simnews | 15
infoexchange
Bowled over at
2011
Conference in Tampa
a range of delicious sides and topped off their energy reserves with
some sweet treats for dessert. Diners then hit the lanes for a few
rounds and a great time was had by all, with some bowlers revealing
award-worthy bowling skills… The trophy for “Highest Individual
Score” was awarded to Tom Luniewski (PG&E-Diablo Canyon), while
“Most Improved Score” went to Bernhard Weiss (L-3 MAPPS). The
“Most Creative Approach” honours were awarded to Jody Brodsky
(STPNOC-South Texas Project) and Lisa Taylor (spouse of Dennis
Based on customer feedback, the presentations were spread over
Taylor (Duke Energy-McGuire)). Last but not least, the prestigious
a two-day period with opening presentations beginning Thursday
“Gutterball Award” was presented to Monika Lufi (spouse of Roger
afternoon. Topics covered on day one included an overview of L-3
Lufi (Axpo-Beznau)) for this noteworthy achievement. Congratulations
MAPPS Power Systems and Simulation projects and achievements in
to all the award winners!
2010 and a briefing on the latest developments in customer service
as well as an informative presentation of the latest technology
updates.
The annual North American edition of the L-3 MAPPS’ Owners
Circle™ Conference (OCC) travelled to Tampa, Florida this year,
taking place on Thursday, 17 February and Friday, 18 February
2011. The conference was again held in conjunction with the
International Conference on Modeling and Simulation Technology
for Power Plants (PowerPlantSim’11), which was held from 14 to
16 February.
Thursday evening featured a networking dinner for conference
participants and their guests. This year’s dinner included a fun-filled
evening of dinner and bowling at Tampa’s Splitsville Luxury Lanes
and Dinner Lounge. Bowlers fueled up on a variety of tasty entrees
including filet mignon, mahi-mahi and chicken parmesan along with
16 | simnews | Issue 33
infoexchange
The group reconvened Friday morning for a presentation covering
migration to Orchid® followed by an informative guest presentation
by Jody Brodsky, simulator supervisor of South Texas Project 1 &
2 at STP Nuclear Operating Co., titled “L-3 MAPPS’ IC Transfer Tool
for Reactor Model Maintenance and the STP Experience.” This
was followed by a live tool review that covered Orchid® Modeling
Environment, Orchid® Configuration Manager, Orchid® Simulator
Executive and Orchid® Instructor Station. Finally participants were
briefed on the topic of Microsoft SharePoint for Document and Data
Management before an opportunity for Q&A and open discussion
brought the meeting to a close.
L-3 MAPPS would like to thank all of the 2011 participants,
with a special thank you to Jody Brodsky for his insightful guest
presentation. We look forward to seeing you all back in San Diego for
the 2012 conference.
If you are a user of L-3 MAPPS simulation products and wish to join
us for future Owners Circle™ conferences or if you would like to be a
co-host, please contact Isis Lopez at isis.lopez@L-3com.com .
July 2011 | simnews | 17
infoexchange
Recent Events
Since the last issue of simnews was published, L-3 MAPPS has
been out and about at various conferences and tradeshows
demonstrating its extensive Power Systems and Simulation
know-how and technologies. A round up of the most recent events
follows.
The following
are upcoming
conferences,
exhibitions an
d seminars w
here you can
expect to mee
t with L-3 MAP
PS Power
Systems and
Simulation.
CONTE 2011
L-3 MAPPS sponsored and exhibited
at the American Nuclear Society’s
2011 Conference on Nuclear
Training and Education (CONTE)
which took place in Jacksonville,
Florida on 6-9 February 2011. We also
presented our solution for “ScenarioBased Testing and Training.”
PowerPlantSim 2011
Immediately after CONTE 2011, L-3
MAPPS sponsored and participated at
The Society for Modeling & Simulation
International’s International Conference
on Simulation Technology for Power
Plants (PowerPlantSim). This event
took place on 14-16 February
2011 in Tampa, Florida. L-3 MAPPS
presentations covered four topics:
• Scenario-Based Testing and Training
• Use of Simulation to Support the Digital Feedwater Controls
Replacement at the Callaway Plant
• The Simulator Input/Output System: 2011 and Beyond
• Implementation of Safety and Non-safety DCS on the
Hongyanhe Simulator
14-17 August 2011
Location
Organizer
Participate
October 2011 (date to
be announced)
Organizer
Participate
28 September 2011
Location
Participate
29 September-1
October 2011
2011 USA Nuclear Generator and
Supplier Executive
Summit
L-3 MAPPS was pleased to sponsor
and to exhibit at the Utilities Service
Alliance’s 2011 USA Nuclear Generator
and Supplier Executive Summit which
occurred 14-17 June 2011 in Grapevine,
Texas. It was the first time that L-3
MAPPS presented its Orchid® Touch
Interface product at a public gathering. See the
Technical Developments section in this issue of simnews for more
on Orchid Touch Interface.
18 | simnews | Issue 33
Event
Location
Organizer
Participate
12-15 February 2012
Event
Location
Organizer
Participate
16-17 February 2012
Event
Location
OCI/OPG Suppliers Day 2011
L-3 MAPPS was on hand at the OCI/OPG Suppliers Day on 14 June
2011 in Ajax, Ontario. This event was put on by the Organization
of CANDU Industries to allow industry suppliers to showcase their
nuclear technology and services to Ontario Power Generation.
Event
Organizer
POWER-GEN Europe 2011
The nineteenth POWER-GEN Europe Conference and Exhibition
took place 7-9 June 2011 in Milan, Italy. L-3 MAPPS was on hand
with a booth showcasing our power plant simulation solutions.
POWER-GEN Europe 2011 had a record 14,917 attendees across
the three events over three days.
Event
Location
Nuclear 2011
In Shenzhen, Guangdong Province, China L-3 MAPPS exhibited at
The 9th China International Exhibition on Nuclear Power Industry
2011 on 6-8 April 2011. This exhibition was organized by China
Nuclear Energy Association (CNEA).
Event
Organizer
Participate
16-17 February 2012
Event
Location
Organizer
Participate
13-15 June 2012
Event
Location
Organizer
Participate
Utility Working Conference and
Vendor Technology Expo
Hollywood, Florida, USA
American Nuclear Society
www.new.ans.org/meetings/m_128
Owners Circle™ Conference
Turku, Finland
L-3 MAPPS
By invitation; for L-3 MAPPS product
owners/users
OCI/AECL Suppliers Day 2011
Mississauga, Ontario, Canada
Organization of CANDU Industries
For OCI members only
India Nuclear Energy 2011
Mumbai, India
UBM India
www.indianuclearenergy.net/
introduction.htm
International Conference on
Simulation Technology for Power
Plants
San Diego, California, USA
SCS
www.scs.org/powerplant
Owners Circle™ Conference
San Diego, California, USA
L-3 MAPPS
By invitation; for L-3 MAPPS product
owners/users
POWER-GEN Europe
Cologne, Germany
PennWell
www.powergeneurope.com/index.
html
2012 Nuclear Generator & Supplier
Executive Summit
Colorado Springs, Colorado, USA
Utilities Services Alliance
www.usainc.org
lighterside
COORDINATOR & GRAPHIC DESIGNER
simnews would like to thank this
André Rochon
issue’s contributors:
EDITOR
R&R International Translation
Specialists Inc.
Milt Caplan (MZConsulting)
Michael Chatlani
Raymond Dimitri-Hakim
Assad Hodhod
Michelle McEwen
Ilson Soares (Eletrobras Eletronuclear)
Bernhard Weiss
Gregory Zakaib
simnews is a publication of
L-3 Communications MAPPS Inc.
www.L-3com.com/MAPPS
© 2011 L-3 Communications MAPPS Inc.
All Rights Reserved.
ANTHEM, ANTHEM2000, AutoChart, CARDs,
Chorus, COMET, Isis, jNet, Orchid, Owners
Circle, ROSE, simnews, SimStudio and Visual
Simex are trademarks of L-3 Communications
MAPPS Inc. All other products are trademarks
of their respective companies.
L-3’s superior training environments use Orchid® simulation products to give plant operators the skills to handle any
emergency response situation. No matter how complex or dangerous, any scenario can be reproduced, monitored
and varied — realistically and in real time. To see how over 35 years of expertise in advanced simulation can make
a very real difference to you today and tomorrow, visit www.L-3com.com/MAPPS.
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