Simulator Phased vs. Full Upgrade Western Services Corpora5on
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1 Simulator Phased vs. Full Upgrade 25 Western Services Corpora5on
2 WSC, Inc. Introduction 2 th Year Western Services Corpora5on
3 WSC Company Overview q q q q q q Technology Driven Company Research Oriented over 2% of gross profit goes into R&D Employees: 85; Mul5disciplinary team of nuclear, mechanical, electrical, chemical engineers, physicists and computer scien5sts, 3% with advances degrees. Headquarters in Frederick, Maryland, USA Main Business - Power Plant Simula5on n Nuclear Power Plant Simulators 4% n Conven5onal Power Plant Simulators 3% n Simula5on Assisted Engineering 2% n Navy and Marine Simula5on 5% n Process and Pipelines 5% ISO 9:25 Cer5fied 25 Western Services Corpora5on 3
4 WSC HQ Loca5on 25 Western Services Corpora5on 4
5 WSC Simula5on Technology High Fidelity Simulaon for use in: q Development of Replica Training Simulators Nuclear, Coal, Combined Cycle & Gas Plants, Solar, Process, Pipeline Part-Task and Full-Scope Simulators Classroom Simulators Web based simulators q Simulaon Assisted Engineering (SAE) System Analysis and Design Human Factors Engineering Logic and Control Tes5ng, V&V Plant Op5miza5on Plant Test and Opera5ng procedures e.g. commissioning procedures 25 Western Services Corpora5on 5
6 WSC Simulator Installa5ons 25 Western Services Corpora5on 6
7 Our Customers 25 Western Services Corpora5on 7
8 Nuclear Full Scope Replica Simulators China, CNPSC Ningde Taiwan, TPC Lungmen Korea and UAE KHNP Shin Kori and Barakah APR4 Northrop Grumman Ship Building BeKs / Knolls Atomic Power Laboratory General Dynamics Electric Boat 25 Western Services Corpora5on USA, APS Palo Verde 8
9 Barakah Three (3) MCR Full Scope Simulators 9 25 Western Services Corpora5on
10 Conven5onal Power Genera5on Large Solar Hydro, Grid Fossil / Coal Desalinaon, Gasificaon, FGD Process and Pipelines 25 Western Services Corpora5on Single & Combined Cycle
11 WSC Training and Engineering Simulators 3KEYSOFTWARE 25 Western Services Corpora5on
12 Simula5on Technology Overview Sokware Products Suite for Comprehensive Plant Coverage 3KEYMASTER Simula5on Plahorm and Modeling Tools - Flagship for this Suite Graphical Engineering Sta5on for Simula5on Development and Control / Instructor Sta5on 2-Phase Flow network Tool Electrical Network Tool Logic & Control and Relay Tools Component Tool and Library 3KEYRELAP5-RT KAERI MARS GE TRAC Adapta5on of INEEL s RELAP-3D, including NESTLE, to run in real- 5me with visualiza5on, provides best-es5mate engineering grade modeling for Thermal-hydraulics and Neutron Kine5cs 3KEYSAA Severe Accident Analysis Models MELCOR / MAAP 3KEYDCS is our solu5on for Distributed Control Systems that provides accurate emula5on for Control and Logic, Man-Machine Interfaces, including trend and alarm displays 3KEYSAFE /3KEYCATALOG Configura5on Management Solu5on for managing the simulator configura5on to the reference plant design through various stages of plant design evolu5on 3KEYTOUCH Alterna5ve Training Delivery Plahorm 3KEYITS/3KEYSTUDENT Web and Classroom based Simulator Lesson delivery 25 Western Services Corpora5on 2
13 Object Oriented Simulation Environment WSC Simula5on Technology Instructor Station Flow Systems Electrical Logic & control 25 Western Services Corpora5on Wiring/Protection 3
14 WSC Simula5on Technology Engineering Grade Models including Idaho National Lab (INL) RELAP5 R/T & 3D Reactor Physics NESTLE Flow Systems Electrical Logic & control 25 Western Services Corpora5on Wiring/Protection 4
15 WSC Simula5on Technology Engineering Grade Models including Idaho National Lab (INL) RELAP5 R/T & 3D Reactor Physics NESTLE MAAP and MELCOR Severe Accident Code 25 Western Services Corpora5on 5
16 Distributed Control Systems DCS Emulation/Virtual Solutions WSC Simula5on Technology MAAP and MELCOR Severe Accident Code 25 Western Services Corpora5on 6
17 Distributed Control Systems DCS Emulation/Virtual Solutions WSC Simula5on Technology Touch Screen Virtual Panels 25 Western Services Corpora5on 7
18 Classroom & Web based Simulators WSC Simula5on Technology Touch Screen Virtual Panels 25 Western Services Corpora5on 8
19 Classroom & Web based Simulators WSC Simula5on Technology Configuration Management System and Product Catalogue 25 Western Services Corpora5on 9
20 Simulator Phased vs. Full Upgrade 25 Western Services Corpora5on
21 Contents Simulator Upgrade Drivers Common Problems with Phased Simulator Upgrades Example of a Phased Simulator Upgrade Reducing Repeve Tasks Conclusion 25 Western Services Corpora5on 2
22 HW and/or SW Obsolescence Upgrade Drivers Moderniza5on of Instructor Sta5on, Environment and Tools Hand-Craked Code, Assembly, FORTRAN, Primi5ve Code Generators lost during the upgrades and ports Plant Uprate, Mechanical Upgrades, Control Upgrades such as Distributed Control Systems (DCS) Ops Training desired improvements, func5onality or fidelity increase: Reactor Modeling, Containment, BOP, etc. Staff Turnover: Inability to maintain current sokware Regulatory changes or ANS/ANSI 3.5 Updated requirements 25 Western Services Corpora5on
23 Typical Plant Phased Approach Por5ng, Environment, IO Upgrades (including Instructor Sta5on, Panel Graphics, IS P&IDs, IO System) Primary Systems Replacement Main BOP Loop Safety Systems, Containment, HVAC Electrical Systems Analog Logic & Controls Distributed Control Systems Miscellaneous Peripheral Devices Auxiliary Systems; air, oil etc. 25 Western Services Corpora5on
24 Problems with Phased approach Incompa5bility between Upgraded and Exis5ng Systems Data or System Inconsistencies Simplified Modeling of Interface Systems Interfaces Omipng or Missing Repeatability of New or Exis5ng Models Ability to Change/Modify Exis5ng Models Scope Changes During Project Execu5on Mul5ple/Repe55ve Tes5ng Requirements General Expecta5on of the Upgrade 25 Western Services Corpora5on
25 25 Western Services Corpora5on Problems with Phased approach
26 Sample Phased Upgrade 23 through Western Services Corpora5on
27 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
28 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
29 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests Full BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS Sokware Port Instructor Sta5on Panel Graphics/P&IDs Interfaced Equipment Transients/ Repeatability Re-snap of Ini5al Condi5ons CMS System Contain/HVAC W73 CTRL Full ATP Tes5ng Necessary 24 Glass tops Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
30 Port & I/S Year Sample Phased Upgrade 8 Full or Acceptance Tests BOP Upgrade Full Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System New BOP Models Replaced BOP I&C Systems Updated Malfunc5ons Updated Remote Func5ons Transients/Repeatability Re-snap of Ini5al Condi5ons Contain/HVAC W73 CTRL Glass tops Full ATP Tes5ng Necessary 25 Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
31 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Tes5ng of Upgraded Items 26/27 Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
32 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS New DCS System Updated Malfunc5ons Updated Remote Func5ons Transients/Repeatability Re-snap of Ini5al Condi5ons Full CMS System Contain/HVAC W73 CTRL Glass tops Full ATP Tes5ng Necessary 2 Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
33 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System New Reactor Auxiliaries Replaced I&C Systems Updated Malfunc5ons Updated Remote Func5ons Transients/Repeatability Re-snap of Ini5al Condi5ons Full Contain/HVAC W73 CTRL Glass tops Full ATP Tes5ng Necessary 22 Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
34 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Tes5ng of Upgraded Items 2/22 Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
35 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Dependence on the FSS Plahorm 24 Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
36 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Containment/HVAC Electrical Systems Updated Malfunc5ons Updated Remote Func5ons Transients/Repeatability Re-snap of Ini5al Condi5ons Contain/HVAC W73 CTRL Glass tops Full ATP Tes5ng Necessary 25 Full Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
37 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System W73 Controls Electrical Systems Updated Malfunc5ons Updated Remote Func5ons Transients/Repeatability Re-snap of Ini5al Condi5ons Contain/HVAC W73 CTRL Glass tops Full ATP Tes5ng Necessary 26 Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
38 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Tes5ng of Upgraded Items 27 Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Reactor Models Fire Protec5on 25 Western Services Corpora5on
39 Port & I/S Year Sample Phased Upgrade Full or Acceptance Tests BOP Upgrade Classroom I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Reactor Thermal-hydraulics and Neutronic Models Updated Malfunc5ons Updated Remote Func5ons Transients/Repeatability Re-snap of Ini5al Condi5ons Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Full ATP Tes5ng Necessary 28 Reactor Models Full Fire Protec5on 25 Western Services Corpora5on
40 Port & I/S BOP Upgrade Year Sample Phased Upgrade Full or Acceptance Tests Full Full 2 Classroom I/O MSIV Upgrade Turb/Gen DCS Full 3 React Aux Sys RM8/23 Full 4 Feed Pump DCS CMS System Contain/HVAC W73 CTRL Glass tops Full Full 5 6 Rod Drive/Ann Reactor Models Full 7 Fire Protec5on 25 Western Services Corpora5on
41 Price Comparison Phased vs. Full 25 Western Services Corpora5on
42 Vendor Price and Customer Tes5ng Price / Cost Full Vendor Customer Tes5ng Phased Vendor Customer Tes5ng 25 Western Services Corpora5on
43 Price / Cost Full Vendor Price/Cost 4 MUSD Total Customer Tes5ng 2.4 MUSD 6.4 MUSD Phased Vendor 4.4 MUSD Customer Tes5ng 4.2 MUSD 8.6 MUSD 25 Western Services Corpora5on
44 Price / Cost Full Vendor Price/Cost 4 MUSD Total Customer Tes5ng 2.4 MUSD 6.4 MUSD Phased Vendor 4.4 MUSD Customer Tes5ng 4.2 MUSD 8.6 MUSD 25 Western Services Corpora5on
45 Price / Cost Full Vendor Price/Cost 4 MUSD Total Customer Tes5ng 2.4 MUSD 6.4 MUSD Phased Vendor 4.4 MUSD Customer Tes5ng 4.2 MUSD 8.6 MUSD 25 Western Services Corpora5on
46 Price / Cost Full Vendor Price/Cost 4 MUSD Total Customer Tes5ng 2.4 MUSD 6.4 MUSD Phased Vendor 4.4 MUSD Customer Tes5ng 4.2 MUSD 8.6 MUSD 25 Western Services Corpora5on
47 Simulator Software Evaluation Phased Upgrade Planning 25 Western Services Corpora5on
48 Reducing Impact of Phased Approach Simulator Systems & Groups Evaluate Simulator Sokware Strength and Weakness Star5ng with the Plant System s List Group Systems based on Interface Requirements and Dependability such as: Reactor and BOP Systems Safety Systems Containment and HVAC Electrical Systems Control Systems etc. 25 Western Services Corpora5on
49 Simulator Systems Evalua5on For each Group Evaluate: Does the System or Group of systems Fidelity and Completeness meet Training needs? Is the Group of Systems Maintainable/Upgradeable? Are Systems in the Group under a Configura5on Management System CMS capable of cross references data vs. models? Any scheduled Plant upgrades impac5ng the System or Group? How will such upgrades be applied to the models 25 Western Services Corpora5on
50 25 Western Services Corpora5on Sample Evalua5on Form
51 Port & I/S BOP Upgrade Year Sample Phased Upgrade Full or Acceptance Tests Full Full 2 Classroom I/O MSIV Upgrade Turb/Gen DCS Full 3 React Aux Sys RM8/23 Full 4 Feed Pump DCS CMS System Contain/HVAC W73 CTRL Glass tops Full Full 5 6 Rod Drive/Ann Reactor Models Full 7 Fire Protec5on 25 Western Services Corpora5on
52 Port & I/S BOP Upgrade Classroom Year 2 3 I/O MSIV Upgrade Turb/Gen DCS React Aux Sys RM8/23 Feed Pump DCS CMS System Contain/HVAC W73 CTRL Glass tops Rod Drive/Ann Reactor Models Fire Protec5on Sample Phased Upgrade Reduces Full Tes5ng to 4 which results in similar price/cost between Phased and Full Upgrades 3 3 Full or Acceptance Tests Full Full Full Full Western Services Corpora5on
53 Conclusion Evaluate Current Simulator System s Strength and Weaknesses Group Systems to Reduce Upgrade Problems Reduce Repe55ve Tes5ng by Vendor and Simulator Staff Keep Simulator Future Maintenance at the forefront when deciding on system upgrades Re-establish configura5on control over the simulator sokware 25 Western Services Corpora5on
54 25 Western Services Corpora5on Ques5ons
55 25 Western Services Corpora5on
56 WSC Contact Informa5on Thank You! Oussama Ashy, Mladen Udbinac WSC, Inc. 796 Crestwood Blvd, Suite 3 Frederick, MD Western Services Corpora5on 56
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