SISTEM DE CONDUCERE CU CACLCULATORUL A TESTELOR MID

Funcţiile de urmărire, control şi supraveghere ale testelor capului MID au fost proiectate şi
implementate în Sistemul de Conducere cu Calculatorul (SCC-MID) pe o structură bazată pe soluţii
modulare atât în ceea ce priveşte partea hardware a sistemului cât şi la proiectarea aplicaţiei software,
bazate pe tehnologii de ultimă oră, care să permită o mare flexibilitate în administrarea şi întreţinerea
sistemului SCC-MID: sistem VME pe care rulează un sistem de operare OS9/68k (sistem de operare
asemănător UNIX-ulului, cu facilităţi de timp real, multi-user şi multitasking), ISaGRAF (software
orientat pe dezvoltarea şi rularea de aplicaţii de control şi conducere automată a proceselor), Hawk
(mediu de programare integrat, ce prevede mecanism de cross-compiler, pentru dezvoltarea de aplicaţii
C++ utilizabile pe platforme bazate pe procesoare MOTOROLA), Suretrack (software destinat gestionării
proiectelor).
Topologia aleasă implementează un sistem de tip reţea deschisă, concept care permite
interconectarea diferitelor platforme software/ hardware (OS9/MOTOROLA şi sisteme MS-
WINDOWS/ix86).
Sistemul de Conducere cu Calculatorul a testelor capului MID (SCC-MID) înglobează atât
modelarea procesului tehnologic fragmentat în module funcţionale independente, dar şi o multitudine de
instrumente dedicate unor funcţii, cum ar fi:
 Simularea în timp real a comportării maşinii atunci când răspunde la comenzile operatorului
uman sau la schimbările de stare ale altor subansamble ale maşinii ca rezultat al altor comenzi,
al legăturilor mecanice sau al interblocărilor tehnologice; prezentarea rezultatelor apărute ca
urmare a funcţionării;
 Crearea bazelor de date, popularea lor cu informaţii, administrarea, instrumentele de întreţinere
şi procedurile de securizare a datelor care sa facă posibilă păstrarea sigură informaţiilor pentru a
fi utilizate concurent de către diferitele programe de aplicaţie, inclusiv datele obţinute la
calibrarea parametrilor tehnologici ai procesului condus şi prezentarea informaţiilor către
operatorul uman;
 Mecanisme de comunicare sigure între task-uri concurente dezvoltate sub diferite medii de
programare facilitate pe de o parte de către controlerul de timp real din nucleul software al
sistemului de operare OS9/68k şi pe de alta parte prin intermediul kernel-ului de ISaGRAF, care
au prevăzute mecanisme de sincronizare între task-uri concurente şi posibilitate de administrare
a datelor sub formă de module de date OS9;
 Administarea I/O pentru funcţii de achiziţie de date în timp real şi instrumente de verificare a
datelor achiziţionate;
 History Docket cuprinzător pentru informaţii legate de sistemul de conducere si date
tehnologice. Instrumente de prezentare flexibile;
 Depanarea şi dezvoltarea aplicaţiei software şi monitorizarea procesului tehnologic condus;
 Vizualizare/Înregistrare, HMI, cu acces local sau de la distanţă pentru programe on-line şi off-
line;
 Proceduri şi regului de administrare integrate pentru utilizatori şi grupuri de utilizatori, folosind
atât funcţii ale sistemului de operare OS9/68k cât şi mecanisme de aplicaţie;
 Administrarea erorilor de manevrare pentru siguranţa controlului tehnologic şi întreţinerea
aplicaţiilor software;
 Deefinirea JOB-urilor tehnologice şi administrarea execuţiei lor.

Interfaţa de proces
Cuplarea sistemului de conducere cu calculatorul a testelor capului MID la dulapul de
automatizare din camera de comandă se realizează prin nivelul ierarhic inferior al acestuia, calculatorul de
proces VME-TARGET, echipat cu interfeţele de proces adecvate (fig.1).
Interfeţele de proces din structura calculatorului VME-TARGET sunt următoarele:
- interfaţă de achiziţie analog/numerică (A/I);
- interfaţă de achiziţie intrări numerice (D/I);
- interfaţă de ieşiri numerice (D/O).
 Interfaţa de achiziţie analog/numerică (A/I) se constituie din sistemul MSCS (Modular Signal
Condition Sistem) destinat aplicaţiilor cu semnale analogice ce provin de la senzori, pe care le amplifică
şi le filtrează. Interfaţează direct module convertoare analog/numerice, cum sunt IDAD sau VDAD. Are
în componenţă:
- opt module SCU (Signal Conditioning Unit) echipate cu câte două piggyback-uri fiecare;
- un modul SCUI (Signal Conditioning Unit Interface) destinat interfaţării directe cu modulul
convertor A/D, IDAD.
Interfaţa de achiziţie analog/numerică (A/I) permite achiziţia datelor analogice din procesul de
testare.
Interfaţa de achiziţie intrări numerice (D/I) este constituită din trei module VMOD-2D (interfeţe
industriale de I/O pentru VMEbus) echipate cu piggyback-uri PB-DIN3 care prevăd 20 de canale
optoizolate (16 pentru intrări de nivel logic şi 4 pentru intrări de stare şi întreruperi). Modul de
funcţionare al acestui piggyback se stabileşte în faza de iniţializare prin înscrierea în registru de control
general a cuvântului de comandă corespunzător. În cazul nostru, acesta este Modul 1 corespunzător
funcţionării unidirecţionale pe 16 biţi.
Interfaţa de achiziţie intrări numerice (D/I) permite achiziţia datelor numerice din procesul de
testare prin conectorii C #1, C #2 şi C #3.
Interfaţa de ieşiri numerice (D/O) este constituită din trei module VMOD-2D (interfeţe
industriale de I/O pentru VMEbus) echipate cu piggyback-uri PB-DOUT2 ce permit sistemului de
conducere cu calculatorul a testelor capului MID să lanseze comenzi (D/O) către proces prin intermediul
conectorilor C #4, C #5 şi C #6.
Număr de semnale I/O:
 digital input: 90
 digital output: 56
 analog input: 60
Numărul total de semnale din proces este de 206, interfaţa de I/O prevăzând un număr maxim de
256 semnale (96 digital input, 96 digital output and 64 analog input).

Fig. 1 SCC-MID
 Dezvoltarea produselor software destinate conducerii testelor capului MID, in varianta actuală, a
demarat în anul 2000 în cadrul unei colaborări cu SC ALCRI SRL. Respectând logica programelor de
centrală s-a dezvoltat driver-ul principal al procesului de testare, sub forma unui proiect ISaGRAF,
plecându-se de la considerarea MID-ului ca fiind un automat cu stări finite. Această abordare, ca şi
facilităţile oferite de structura hardware au condus la obţinerea unui sistem de conducere cu o foarte mare
flexibilitate şi fiabilitate.
Rezoluţia pe 16 biţi a convertorului A/D, IDAD16, utilizat ca şi viteza de conversie foarte mare a
acestuia a permis includerea de filtre în driver-ul de I/O pentru mărimile de intrare analogice. Driver-ul de
I/O realizează citirea mărimilor de intrare analogice (64) şi digitale (96), precum şi înscrierea ieşirilor
digitale (64). Cu toate aceste timpul total de baleere a tuturor canalelor de I/O împreună cu timpul
consumat pentru scrierea valorilor semnalelor de intrare în zona de memorie alocată fiecăruia şi a
semnalelor de ieşire la porturile corespunzătoare, nu depăseşte 10 ms.

EXPERIMENTAL MODEL OF THE SIMULATOR (MESI)

Hardware Structure
To reach a high quality technical and economic standard level, of the operation, exploitation,
maintenance activities, on Fuel handling System, considered useful development of a high performance
simulator equipment, allowing mainly, training by practice, and initial or periodic of the FHS operation
staff’s skills, and the impact study of some changes in the system structure or parameters, before bringing
in operation of these changes [3].

As a first stage in its execution proposed making of an experimental model simulator MESI
allowing setting the requirements and fabrication details, both for the SISMC simulator hardware,
especially for the software kit shall be designed and implement on it. Shall be designed and verified,
before implementing, a large events set in FHS operation, also, that require from operator to identify and
apply the solution to recover the normal operation state.

MESI reproduce the minimum required of equipment and instruments existing in the control
room, for partial but coherent simulation of the technological installations feedback from FHS. The
technological area covered, from economical and practical reasons, shall focus exclusively on simulation
of F/M head exploitation, during operations developed on the fuel channel, considering this fact sufficient
to reach the goal for the equipment has built.

In fact, MESI allows the accurate execution of the entire operation set developing commonly
during refuelling of the nuclear fuel in reactor, both in the automatic and manual working regime,
confined to operate only on the fuel channel, indifferently the machine is upstream or downstream
working where supply fresh fuel or receive the spent fuel.

The experimental simulating equipment (see Fig.2), consists of three bodies: two desks, identical
sized, including the control and checking elements (switches, lights, analogic and digital instruments,
automatic controller), and a third body, central placed and lower height, sufficient to connect the process
computer assigned.
 Fig. 2 MESI - The Experimental Model of Simulator

The desks are structured on sections (or panels), having the following constitution or functions:
 control and alarm of the in/out positions of the left and right separator stoppers; control and alarm the
lock/unlock positions for the locking latches of the stoppers.
 control and alarm the in/out positions of the left and right separator feelers (sensing element); indicate
the feeler’s positions.
 control and alarm the in/out positions of the left and right separators retractors; indicate the retractors
positions.
 control and indicate the advanced/retracted positions of Z ram; signals to lubricate telescopic ram
assembly.
 control and indicate the advanced/retracted position of B ram; control and indicate the control;
indicate the supply flow rate, selection and indication of the selected force for ram driving.
 order the electric power supply of the simulator; selection of the by-pass inter-locking position for the
B ram, stoppers, feelers, magazine and high pressure valve.
 driving of the clockwise/counter-clockwise rotation of the magazine; fine/coarse indication of the
magazine selected job position
 indication of the magazine supply temperature; flow rates indications on the supply and return lines;
driving of high pressure valves, of magazine supply and return.
 control the magazine water supply pressure; indication, selection and alarm the pressure level, alarm
the magazine water temperature.

In the manual working mode, all the rotary switches on the simulator front panels are on "manual"
position. The manual controls, performed at the experimental simulator desks, have send to process them,
as analogic or digital inputs, to the process computer, following as through its analogic or digital outputs,
to signal or indicate information about equipment or simulated elements on desks.

In the automatic working regime all the rotary switches of the desks are actuated on "automat".
Using the process computer in the automat working regime can be issued controls from assigned
keyboard, to perform step by step, semi-automatic or complete automatic simulation. Starting of the
automatic control is lightening on the control panels, by digital outputs of the process computer. On the
panels of two bodies shall be indicated and signalized the equipment simulated states by analogic and
digital outputs supplied by process computer.

Software Development System

The process computer is a OS9 machine, PEP Modular Computers manufactured in Germany,
with VM42 motherboard, equipped with Motorola MC68040 CPU. Process interface from OS9-VME
computer structure ensures type and number of simulation signal for the experimental model, being
equipped with appropriate analog and digital I/O modules.
 The main programming environments used to develop simulation software for fuel handling
system assemblies included in the experimental model are installed on MS-WINDOWS/ix86 type
computers, the chosen type of topology implementing open network concept, allows interconnection
different software/hardware platforms, between different development systems and VME system running
an operating system OS9/68k with facilities for real-time multi-user and multitasking:
 ISaGRAF allows the implementation of logical part of the software package, data management and
data acquisition.
 Facilities for Historian viewing and recording for analog and digital values from simulation process,
are implemented in LabView, graphical programming language.
 Acquisition tasks and system tools of the simulator are developed using the cross-compiler Microware
Hawk.

The development system provides facilities for viewing / storage / printing logs and operating alarms.
Viewing evolution of technological parameters in graphical form sizes (in engineering units), is an
important component of the experimental model, also hosted on Development System.

Simulation Algorithms
Computer simulation of an existing physical system involves creating its mathematical model. Such a
model is often obtained as a result of the identification system or less frequently based on structural
analysis, where is possible.

Significant resources have been used for modelling distributed technology of independent functional
modules, designing and testing tools dedicated to functions such as:
 Real-time simulation of machine behaviour when responding to commands from the human operator
or status changes of other parts of the machine as a result of other controls, the mechanical linkages or
interlocking technology;
 Creating databases, populating them with information, administration, maintenance tools and data
security procedures to enable safe storage of information to be used concurrently by different
application programs, including data from the calibration of technological parameters and present
information to the human operator;
 Secure communication mechanisms between concurrent tasks developed in different programming
environments;
 Operational administration for functions of real-time data acquisition and acquired data verification
tools;
 Viewing / Recording, HMI, with local or remote access for programs on-line and off-line;
 Integrated management procedures and rules for users using both operating system functions and
mechanisms OS9/68k application;
 Administration of handling errors and software maintenance;
 Defining the technological jobs and manage their execution, for mode with automatic controls of
experimental model.

Example of Magazine Pressure Control Valve Modelling:

The control element of the pressure in the magazine is represented by the PCV pneumatic valve,
assembled on the magazine return circuit. The valve is supplied with electro-magnetic positioner
receiving the signal from the PT pressure transducer. For damping the pressure oscillations in the F/M
magazine, the TK pressure accumulator is assembled upstream PCV valve. For initial setting of the
maximum pressure level is using the SO hydraulic resistance by SV valve (see Fig.3).
 Fig.3 – The control circuit of the pressure in the F/M magazine

To determine the mathematic model of control valve is using the diagram:

Fig. 4 – The pneumatic control valve

The forces calculation:

2
d H dH
m 2
  k  H  A  Pm  F p (1)
dt dt
where k  H – elastic force of spring
dH
  FF - friction force
dt
Q 1

Q100 1 (2)
1   ( 2  1)
kV
After calculus by linearisation around the point H = H0 results:
m d2  d A
 2 (H )   (H )  H   Pm (3)
k dt k dt k
H  H  H 0
Pm  Pm  Pm 0
 d  Q  dkV  Q
Note P       , and q 
 dkV  Q100  dH  H  H 0 Q100
m d2  d A q
 2  q     q   q   Pm (4)
k dt k dt k
q ( s)
Applying the Laplace transformation to above differential equation and developing the ratio :
Pm ( s )
q ( s) b
 , so the transfer function of the PCV is:
Pm ( s ) a2  s  a1  s  1
2

b 0.0852
GPCV ( s )   (5)
a2  s  a1  s  1 2.456  s 2  1.25  s  1
2

The notations / symbols are:

A p  m
b ; a1  ; a2 
k k k
m – mobile element mass;
H – plug stroke;
k – elastic factor of the spring;
Pm – pressure on diaphragm;
A – section of the diaphragm;
μ – viscous friction factor;
q – flow rate;
Q – flow rate to any opening;
Q100 – flow rate to maximum opening.

To relate between flow rate and pressure considering relation between the volumetric flow rate and the pressure
drop:
Pr
Q  kV  ; kV  f ( , s ) – the specific flow factor;  - the specific leakage factor;

Using the simulation environment Matlab-Simulink is getting the behaviour simulation of the PCV control valve, at
step impulse:

Fig.5 - The PCV response at step impulse

The Fuelling Handling Machine is a system by which the nuclear reactor is periodically refuelling with
fresh fuel, in order to support the fission reactions and generating power constantly. Well exploitation and
proper operation of the system has influence, as consequence, on efficiency and safe operation of NPP,
generally.

Performing of a complete simulator of FHS from NPP is a point-full, efficient and advisable solution for
completion of the control room F/M operator’s training program in nuclear reactor.

Experimental simulator MESI is an instrument, designed to set the requirements and fabrication details
for the SISMC simulator, especially for the software kit shall be implement on it.

The SISMC simulator consist of a number of control desks, identical to those from Cernavoda CANDU
600 reactor control room, where operators being in training will interact with the equipment, a trainer’s
console where the applications shall start and run, as well as the computing equipment providing the
process modelling and simulated execution of the controls.

Using in the training program, or operator’s testing, checking and evaluation of such instruments give a
lot of advantages, but the most important may be that to increase the training cycle quality and allowing
the simulated testing in condition identical of the real case, of manual or automatic interventions in
solving of potential operation events of technological installation.

In future, the Institute for Nuclear Research from Pitesti - Romania, will be involved in building of a simulator for
Fuelling Handling System part dedicated to reactor control room, useful for operator’s training program.