FPGA- based technology and systems for I&C of existing and ......South-Ukraine-2 2007, 2008...

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 RADIYUkraine

Research-and-Production Corporation “Radiy”

Table of Contents

- Introduction- FPGA – based I&C Systems which are in

operation- RADIY platform- FPGA – based I&C Systems - Conclusions

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Closed Joint-Stock Company “Research-and-Production Corporation “Radiy”

IntroductionTraditional 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.

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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

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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

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Reactor Trip System (diversity)22 sets (primary and diverse)

Zaporozhye-1 2003, 2004Zaporozhye-3 2004, 2006Zaporozhye-2 2009Rovno-1 2007Rovno-2 2007Rovno-3 2005, 2007Rovno-4 2004Khmelnitsky-1 2007Khmelnitsky-2 2004South-Ukraine-1 2005South-Ukraine-2 2007

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FPGA – based I&C Systems in operation

Reactor Power Control and Limitation System

8 sets

Zaporozhye-1 2008Rovno-3 2007Rovno-4 2006Khmelnitsky-1 2008Khmelnitsky-2 2004South-Ukraine-1 2005South-Ukraine-2 2007

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Engineered Safety Features Actuation System

13 sets

Rovno-1 2007, 2008 Rovno-2 2007, 2008 South-Ukraine-1 2005, 2006, 2007South-Ukraine-2 2007, 2008Kozloduy-5 2009Kozloduy-6 2008, 2009

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Rod Control System (with Power Supply Equipment for Control Rod Drive)

1 set

Testing operationsuccessfully completed inZaporozhye NPP

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Regulation, Control and Protection Systemfor 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

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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.

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RADIY platform

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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

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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

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RADIY platformThe main principles of RADIY platform development (cont.):

- Diagnostic functions are separated from informationand control functions;

- Absence of a direct connection between computing processes;

- Software and FPGA-application verification is based onmulti-components V-shape life cycle;

- Use multi-components distributed data processingstructure 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.

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RADIY platform

“Radiy” Platform meets the safety requirements of national regulationsof Ukraine for nuclear applications.

Ukrainian safety regulations for I&C systems at nuclear applicationsact in full compliance with requirements of international IEC standardsand IAEA recommendations.

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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)

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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

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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

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FPGA – based I&C Systems technologyThe 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

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Design procedure for electronic FPGA-application and its verification

- Development of block-diagrams according to controlalgorithms- Development of FPGA electronic design (program modelsof control algorithms) in IDE (Integrated Development Environment) - Compliance assessment of signal formation algorithmblock-diagram program models in IDE to signal formationalgorithm block-diagrams- Electronic Design Implementation- Functional (black-box) testing- Time modeling

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FPGA – based I&C Systems technologyTime 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

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FPGA – based I&C Systems technologyTime 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)

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The 1st day

The 9th day

Kozloduy NPP-5Safety System 2

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The 14th day

The 18th day 25


Kozloduy NPP-5Safety System 2


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.

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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.

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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: [email protected]

http://www.radiy.com


mailto:[email protected]�

FPGA- based technology and systems for I&C of existing and ......South-Ukraine-2 2007, 2008...

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