International Conference on Opportunities and Challenges for Water Cooled Reactors in the 21st Century Vienna, Austria, 27 30 October 2009 FPGA- based technology and systems for I&C of existing and advanced reactors E. Bakhmach, O.Siora, V. Tokarev, S. Reshetytskyi, V. Kharchenko, V. Bezsalyi Research & Production Corporation RADIY Ukraine Research-and-Production
Table of Contents - Introduction - FPGA based I&C Systems which are in operation - RADIY platform - FPGA based I&C Systems - Conclusions 2
Introduction Traditional digital technologies are characterized by some weak points and therefore have several disadvantages: - Possibility to have common cause failures - Complexity of documentation and testing - Complexity of safety evaluation - Delay to project implementation - Project cost increase Radiy Company has designed and developed advanced technology based on FPGA. We offer the tool that can minimize negative effects of traditional digital technologies. 3
Introduction Radiy Company is located in the city of Kirovograd, Ukraine. Form of ownership a private company. The company s personnel is 1300 employees. By its structure Radiy is a research and production enterprise with design offices, production and testing facilities. The design offices are specialized in several areas: - Control systems for technological processes - Fire prevention automation - Forced power supply equipment Production of electronic and electro technical modules and cabinets is made by advanced equipment Testing and qualification facilities are equipped with advanced technologies to identify possible production weaknesses and to demonstrate products robustness to external effects. Quality Assurance System is certified 4
FPGA based I&C Systems which are in operation Radiy Company have been using FPGA technology for safety-critical systems at NPPs Currently more than 40 FPGA-based systems have been implemented in Ukrainian NPPs (Zaporozhye, South Ukraine, Rovno, Khmelnitskiy) and in Bulgarian NPP (Kozloduy): - Reactor Trip System - Reactor Power Control and Limitation System - Engineering Safety Features Actuation System - Rods Control System - Regulation, Control and Protection System for research reactor 5
FPGA based I&C Systems which are in operation Reactor Trip System (diversity) 22 sets (primary and diverse) Zaporozhye-1 2003, 2004 Zaporozhye-3 2004, 2006 Zaporozhye-2 2009 Rovno-1 2007 Rovno-2 2007 Rovno-3 2005, 2007 Rovno-4 2004 Khmelnitsky-1 2007 Khmelnitsky-2 2004 South-Ukraine-1 2005 South-Ukraine-2 2007 6
FPGA based I&C Systems in operation Reactor Power Control and Limitation System 8 sets Zaporozhye-1 2008 Rovno-3 2007 Rovno-4 2006 Khmelnitsky-1 2008 Khmelnitsky-2 2004 South-Ukraine-1 2005 South-Ukraine-2 2007 7
FPGA based I&C Systems which are in operation Engineered Safety Features Actuation System 13 sets Rovno-1 2007, 2008 Rovno-2 2007, 2008 South-Ukraine-1 2005, 2006, 2007 South-Ukraine-2 2007, 2008 Kozloduy-5 2009 Kozloduy-6 2008, 2009 8
FPGA based I&C Systems which are in operation Rod Control System (with Power Supply Equipment for Control Rod Drive) 1 set Testing operation successfully completed in Zaporozhye NPP 9
FPGA based I&C Systems which are in operation Regulation, Control and Protection System for research reactor Was developed for research reactor VVR-M (Nuclear Research Institute in Kyiv) based on tested and approved equipment for power reactors. Research reactor VVR-M was successfully put into operation in March 2008 after I&C and electrical parts modernization 10
RADIY platform The above-mentioned systems are built on the Digital Radiy Platform. Radiy Platform consists of hardware components and software. The hardware includes limited number of cabinets (11) and block modules (16) of different designation. For example: - Protection forming modules, - Input analog and digital signals, - normalizing converter modules, - analog and digital output modules, - actuator control modules. 11
RADIY platform 12
RADIY platform To provide diversity oriented solutions for control systems we are using FPGA from different vendors (e.g. Altera & Actel). Software (upper level): - reception of technological and diagnostic information, - visualization of information on every control algorithm, - visualization of diagnostic information on the status of functional module components. - registration, archiving, selection and display of information 13
RADIY platform The main principles of RADIY platform development: - All control algorithms performed only on FPGAs: - FPGA-applications have clear and well defined structure; - FPGA-applications and schemes of control technological algorithms have direct equivalent; - Simplification of development and verification processes and reduced number of developmental errors; - Ease of integrating, commissioning and licensing digital I&C systems important to safety of NPPs 14
RADIY platform The main principles of RADIY platform development (cont.): - Diagnostic functions are separated from information and control functions; - Absence of a direct connection between computing processes; - Software and FPGA-application verification is based on multi-components V-shape life cycle; - Use multi-components distributed data processing structure with heterogenic networks; - Use of maximal possible quantity of own pre-developed hardware and software with positive service history for design of new I&C systems. 15
RADIY platform Radiy Platform meets the safety requirements of national regulations of Ukraine for nuclear applications. Ukrainian safety regulations for I&C systems at nuclear applications act in full compliance with requirements of international IEC standards and IAEA recommendations. 16
FPGA based I&C Systems technology - Radiy FPGA-based technology makes it possible to perform all the control functions for nuclear installation: regulation, interlock and protection; - This technology is based on the principle that FPGA chip is taken as a part of hardware and electronic FPGA-application is taken as a software part. - All critical functions are realized only in the form of electronic FPGA-application ( the main reason for common cause failure is removed. - Radiy component Platform is the basis for designing control systems which consist of upper and lower level. - all critical functions are realized at the lower level (algorithms of control/regulation, interlock and protection) 17
FPGA based I&C Systems technology - One way information flow is organized between levels from lower to upper level (any impact of the upper level on the lower level is excluded) - Software is used only to solve secondary tasks: - signal reception and processing, - information exchange between system components, - diagnostics, - archiving, - providing man-machine interface. Software amount is decreased Software verification expenses are reduced 18
FPGA based I&C Systems technology - This technology-based systems have short response time; - The systems response time does not depend on the number of actuated work algorithms (it is provided by parallel simultaneous processing of all system algorithms) - Simplicity and short time required for making changes to working algorithms ( no need to change the hardware - All the upgraded systems in nuclear applications meet safety requirements stipulated by existing rules and regulations 19
FPGA based I&C Systems technology The design stages of developing control systems based on FPGA - System Requirements development - Technical specification development (is verified to see the compliance with System Requirements - Design process (hardware, software, technological algorithms projects), verification to see the compliance with Technical Specification - Hardware production, software coding and making electronic FPGA application (testing) - Control system integration, validation and qualification testing 20
FPGA based I&C Systems technology Design procedure for electronic FPGA-application and its verification - Development of block-diagrams according to control algorithms - Development of FPGA electronic design (program models of control algorithms) in IDE (Integrated Development Environment) - Compliance assessment of signal formation algorithm block-diagram program models in IDE to signal formation algorithm block-diagrams - Electronic Design Implementation - Functional (black-box) testing - Time modeling 21
FPGA based I&C Systems technology Time frames for Radiy Platform -based projects implementation NPP Kozloduy, Unit 6 (2-nd safety system) - March 2008 the Contract signed - May 2008 the source data for system design received - August 2008 - Factory Acceptance Test completed - 01 September 2008 - old equipment dismantling started - 05 September 2008 new equipment installation started - 22 September 2008 2-nd safety system is put into operation 22
FPGA based I&C Systems technology Time frames for Radiy Platform based projects implementation NPP Kozloduy, Unit 5 (2-nd safety system) - 18 April 2009 old equipment dismantling started - 05 May 2008 2-nd safety system is put into operation NPP Unit 6:2-nd safety system modernization time was 23 days NPP Unit 5:2-nd safety system modernization time was 18 days NPP Unit 6:1-st and 3-rd safety systems modernization time is 15 days/ safety system (September- October 2009) 23
FPGA based I&C Systems technology Kozloduy NPP-5 Safety System 2 The 1 st day The 9 th day 24
FPGA based I&C Systems technology Kozloduy NPP-5 Safety System 2 The 14 th day The 18 th day 25
FPGA based I&C Systems technology Time frames for Radiy Platform -based projects implementation The retrofit time was so optimistic due to the following factors: - Availability of Digital Radiy Platform - Design and implementation features of electronic FPGA-projects - Factory Acceptance Test characteristics: quality, way of organization and intensity - Radiy Platform- technology flexibility, that provides try-outs of actuators and systems at power units before all the cable connections are done and intellectual part of the system is checked out - Cable connection work optimization. 26
Conclusions Radiy Platform technology designed and developed by Radiy Company: - Is qualified for complex solutions for nuclear installations of different types - Is an advanced tool for retrofit and modernization of NPP power units aimed at life cycle extension - Is able to support licensing processes - Facilitates reducing financial expenses and time for control systems design and development. 27
Thank you very much for your attention! Company Radiy 29 Geroyev Stalingrada street, Kirovograd, Ukraine Tel.: +38 (0522) 37 30 20 Fax: +38 (0522) 55 51 79 E-Mail: marketing@radiy.com http://www.radiy.com