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Digital, Information and Communication Technologies

for safer and more efficient outages in nuclear power plants

From concepts to actual implementation

Laurent Coudert et al.EDF Research & Development, Chatou, France

EPRI - Technology for Productivity Improvements, Charlotte, NC, 29th – 30th June 2010L. Coudert et al.

A historical opportunity to implement new technologies on nuclear power plants

The portfolio of projects dedicated to Information & Communication Technologies

A focus on the current developments on the Advanced Outage Control Room

Timeline, expected gains & further steps

Presentation topics


The story

Increase plant capacity factor

Improve human performance

Prepare the arrival of newcomers (‘Generation Y’)


Increase plant productivity factor

Look for gain sources on the outage critical pathContainer handling in the reactor buildingInformation gathering prior to changing plant statusCritical line-ups

Better anticipate equipment failures

Reduce marginsPower ramping after refueling


Improve human performance

Avoid human errorsHazardous situations / line-upsEquipment disambiguation

Improve operational communicationData retrieval on fieldCommunication between field, outage control room, main control room


Prepare the arrival of newcomers

Knowledge capture / elicitation

Improved training tools & methodsSimulate agent behaviorBenefit from augmened reality to see hidden parts or invisible phenomenaInclude physics and logic models to simulate the effects of improper actions

Credit: BMW


What we need

Look for gain sources on the outage critical pathBetter anticipate equipment failuresReduce marginsAvoid human errorsImprove operational communicationKnowledge capture / elicitationUse virtual reality for training

Look for gain sources on the outage critical pathBetter anticipate equipment failuresReduce marginsAvoid human errorsImprove operational communicationKnowledge capture / elicitationUse virtual reality for training

FunctionsTechnologies

Modernization projects


Functional blocks

• Outage activities simulation

• Prejob briefing• Worker training

• Outage activities simulation

• Prejob briefing• Worker training

Virtual RealityVirtual Reality

• Tagout & line-up preparation

• Line-up error detection

• Tagout & line-up preparation

• Line-up error detection

XML-based P&IDsXML-based P&IDs

• Information display• Collaborative, interactive

surfaces

• Information display• Collaborative, interactive

surfaces

Advanced HSIsAdvanced HSIs

• Early equipment failure• Power ramping aids• Early equipment failure• Power ramping aids

Data processingData processing

• Information tagging• Information aggregates &

mash-ups• ‘Social networks’

• Information tagging• Information aggregates &

mash-ups• ‘Social networks’

Information processingInformation processing


Technical blocks

• Wireless technologies & protocols for data / image / voice

• Cyber security solutions for wireless

• Wireless technologies & protocols for data / image / voice

• Cyber security solutions for wireless

Wireless comsWireless coms

• RFIDs• OCR• 2D bar codes

• RFIDs• OCR• 2D bar codes

Equipment/Room identification

Equipment/Room identification

• Advanced handheld devices

• Software & operating systems for handheld

• Advanced handheld devices

• Software & operating systems for handheld

Handheld appsHandheld apps


The enablers: a set of significant revamping projects aiming at lifespan extension

The “plain old CMMS” will be replaced with an Enterprise Asset Management system by 2013 opportunity to

Rethink work processesUpgrade communication networks and implement wireless

The Main Control Rooms of the 1,300 MW series will be revamped starting from 2015 on


The virtuous circle

Work processWork process

Information system

Information system

Communicationnetworks

Communicationnetworks

ICT, DTICT, DT


A historical opportunity to implement Information & Communication Technologies on Nuclear Power Plants

The portfolio of R&D projects dedicated to Information & Communication Technologies



Presentation topics


A portfolio of projects addressing the challenge of new technologies implementation

Customer-oriented projectsCross-fertilization between nuclear, fossil and hydropower generation

Experimental ApproachHuman Factors Approach


A portfolio of cross-fertilizing projects

HydroHydro

Equipment monitoring and diagnosticsEquipment monitoring and diagnostics

Modernized Information and I&C Systemsin Hydro Generation

Modernized Information and I&C Systemsin Hydro Generation

FossilFossil

New-built CCGT Operations & MaintenanceNew-built CCGT Operations & Maintenance

Modernized Information Systemsin Fossil Generation

Modernized Information Systemsin Fossil Generation

NuclearNuclear

Demonstration platformDemonstration platform

Plant Performance Optimization

Plant Performance Optimization

Improved Performance of Field Operators

Improved Performance of Field Operators

Advanced Outage Management and

Supervision

Advanced Outage Management and

Supervision

Advanced outage preparation

using 3D visualization

Advanced outage preparation

using 3D visualization

Improved worker training

Improved worker training

Innovative Digital Technologyand Network Infrastructures

Innovative Digital Technologyand Network Infrastructures


Design & deployment methodology

Human FactorsEach of these new tools meets an actual need within the nuclear plants day-to-day environment These new tools are adapted to end-users within the context of their work situation Specific coaching during the transition period due to work practices modification is planned

Enterprise architectureFrom computerized systems to information systemsDefine current work practicesDefine the targetSpecify the evolutions needed (work process vs. IT)

Strong partnership between R&D and nuclear operationsTechnology and budget roadmap discussed with Nuclear Operations managementMock-ups for collaborative design and communication towards top managers“Partner” sites for work practice observations, collaborative design and socio-technical studies


Interactive P&IDs for improvedfield operators performance

Process diagram

Application : Pre-job briefing and work execution

On-field procedures with links to:Real-time process dataWork orders / Clearance / Tag-out data (EAM)

… based on XML grammar for straightforward data exchange & translation

Consistency verification

2.6 bar

Procedure


3D visualization for outage preparation

TOMORROW: Extensions of 3D visualization capabilitiesMore models in point clouds or 3D CAD objectsDefinition of prohibited areas during gamma-ray testingsUse for pre-job briefing

TOMORROW: Extensions of 3D visualization capabilitiesMore models in point clouds or 3D CAD objectsDefinition of prohibited areas during gamma-ray testingsUse for pre-job briefing

Model of the turbine hall – Saint-Alban NPP Reactor Building model of a 900 MW 3-loop station

TODAYContainers mobilization inside the containmentHeavy equipment maintenance / replacement (e.g., Steam Generator)


3D visualization: other example

What the camera sees

Execution: no obstacle

Camera

What the camera will

see

‘Virtual preparation: find points of view with no obstacle


Power ramping aids

Dedicated HSIsCoupling with real-time simulation






Presentation topics


The chessboard of outage supervisionOutage Control Room

Main Control Room

Radiation Monitoring Center

Padlocking office

Communication Networks

A network of playersexchanging information in outage

Work SitesWireless Networks


Cattenom NPPThe Outage Control Room

Individual work spaces

Individual Workstations

Guests work spaces

Shared visualization

Video surveillance Planning White Board Logbook


Potential productivity improvements

Share information within people and organizationsLevel of emergencyInformation type (photographs, sound, text…)Level of interaction required (factual / needing appraisal)Role & location of the information recipient in the organization

Design relevant collaborative & decision-making toolsOutage planning not sufficientDeeper levels of information needed, e.g. sub-tasks, task completion… in one clickAggregation with other information necessary, e.g. operator logs

Improve experience feedback processDifferent timelines

HandoffsDuring outageIn preparation of the upcoming outage

Different technologiesVoice recognition“Context-aware” documents


Information sharing modelToday: centralized model

Continuous log database

Structured Information

Collection

Mobile Information Collection

Base

Outage planning enrichment

On fieldinformation collection

Multiple reportings

Search Engines

Tomorrow: distributed model with mobility


Information displays

Adapt information to hardware: PDA, ePaper, PC, Image wall, interactive surfaces…


EDF Development roadmap

Data aggregation

Individual Shared Collaborative

Outage manager

TagoutField operators

Customized portal Multitouch interactive interfaces

Outage Planning Interactive Visualization

Business Intelligence For Outage

Maintenance,Tests

Field Data collection




A focus on the current / upcoming developments on the Advanced Outage Control Room


Presentation topics


Value-driven projectsYearly portfolio budget for nuclear generation = 8 M€Examples of Net Present ValuesDiscount rate: 10%

3D in the Reactor Building for container mobilizationDevelopment costs ~ 4.5 M€Maintenance and training costs ~ 1 M€ over the next 10 yearsEstimated availability gain ~ 40 days / year (fleet)

NPV ~ 100 M€

Aids for field operatorsDevelopment costs ~ 3.2 M€Deployment costs ~ 1 M€Estimated availability gain ~ 1 d/outage (tagout + lineup), 0.1 d/outage (operator rounds)

NPV ~ 65 M€

Plus many qualitative benefits such as reduction of safety / radiation protection eventsPlus many qualitative benefits such as reduction of safety / radiation protection events


Projects timeline (1/2)

DesignFunctional analysis Mock-ups

2008 2009 2010

Line-ups visualization

OCC collaborative technologies

Power ramping aid mock-up

VR-based training tools


Need for a robust network infrastructure

Spend more time on fieldImprove operational communicationIncrease the volume of data exchanged between the field and the decision centers

Broadband AND Low-Power Wireless NetworksEstimated cost for a PWR unit: 1 M€

What has been done:Studies on the potential impact of Wifi transmissionsStudies on the mobility ecosystem in Nuclear Power Plants

Cyber securityChoice of the “right” handheld terminal“Transmission mix”: DSL vs. Wifi vs. optical fibers…

Expect wireless infrastructures rollout to start in 2011

What has been done:Studies on the potential impact of Wifi transmissionsStudies on the mobility ecosystemmobility ecosystem in Nuclear Power Plants

Cyber securityChoice of the “right” handheld terminal“Transmission mix”: DSL vs. Wifi vs. optical fibers…

Expect wireless infrastructures rollout to start in 2011


Projects timeline (2/2)

Mock-ups

2008 2009 2010

Implementation

Mock-ups Implementation

2011 2012

Follow-up onOCC collaborative technologies

Augmented reality

3D for maintenance

On site experiment: field operators mobile / wireless applications


Example of further steps: augmented reality

Augment perception (visual, auditive, tactile)

In real-time

By superimposing fictive 2D or 3D elements

Credit : MeilleursAgents.com


Augmented reality: potential applications

Use of 2D layouts to facilitate navigation within the facility in augmented reality (AR) or virtual reality (VR)

AR mode : superimposition of 3D information on the 2D layout

VR mode: virtual camera positioningusing map tracking


Augmented reality: roadmap

Improve algorithms for faster and more reliable image / map recognitionScreen the necessary information to display on navigation aidsUse laser scansProvide mobile AR applications

Real-time image processing with limited processing capabilities


Display of 3D objects on as-built laser scans


Lessons learned

Completion of the R&D projects does not mean immediate on-site implementation

Need to coordinate technology-driven projects : IT projects (e.g., EAM implementation), Wireless LANs / Wireless sensor networks, Handheld devices…

Establish the technical standards in nuclear power stations (e.g.: wireless sensors)

Solve the pending issues (technical / related to work processes)


Many thanks to…

R&DFabrice SaintamonSamuel ParfouruGuillaume ThibaultAlain SchmidSandrine TonnoirPierre NguyenYves DenayrollesCecilia de la GarzaNathalie de BelerGeneviève FilippiVéronique DuwigChristian BouchenyFrançois DionisRenaud Aubin…

Nuclear operationsJean-Eric BouletCatherine Vielle-Blaya

Questions?

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