July-August 2019 NPJ

Nuclear Plant Journal, July-August 2019 NuclearPlantJournal.com 37 Integrated Configuration and Change Management On a large project such as theAP1000 I&C system, with multiple design organizations and suppliers throughout the world, very robust integration and configuration management processes were necessary to assure success. The AP1000 I&C design process evolved from processes previously used on large- scale integrated digital I&C system deployments supplied by Westinghouse and approved by eight different regulators throughout the world. Change management and error- tracking processes provided the ability to track implementation through hardware and software releases to support system testing and site commissioning activities. These processes were essential to managing agile implementation of a high volume of changes during the commissioning of four units in parallel in China, while providing site flexibility in implementation and preserving the qualification of previous testing. The robust processes and supporting tools applied throughout the AP1000 plant I&C design and implementation process have direct applicability to operating plants, and have been used to improve our standard practices for implementation of I&C upgrades. Safety SystemTesting The factory testing of the AP1000 plant safety systems was one of the most comprehensive and exhaustive in Westinghouse’s history, with test reports exceeding 100,000 pages. This level of testing was primarily driven by an increased focus on requirements management to confirm that each requirement was fulfilled and documented. To increase the quality and speed of the testing, Westinghouse designed and validated extensive testing and signal simulation equipment, including a display capture tool that automatically monitors user interface screens. The integrity of this testing was so strong that it became the foundation for streamlining the safety system implementation and testing process, which was recently presented to the NRC. The NRC subsequently approved a reduction in “Nth of a Kind” factory testing for future Common Q systems as described in the NRC’s “Final Safety Evaluation for Westinghouse Topical Report WCAP-16096-P/NP, Revision 5, ‘Software Program Manual for Common Q Systems,’” (ML18270A029). Commissioning and Startup Testing In a first-of-a-kind new plant build, the I&C system is a critical resource required to support plant commissioning and startup. Additionally, during the commissioning process, agile processes to support implementation of emergent design changes and error corrections are required to maintain the overall project schedule. In support of the initial startup of the four AP1000 units in China, Westinghouse formed a cross-functional team of technical experts and project leaders to assess, prioritize and plan the I&C change implementation. This allowed the I&C teams to effectively deliver those I&C changes on a very short timeline, achieving one-day turnaround of critical changes when required to support site needs. As a result, the AP1000 I&C systems were never on the project critical path. The processes used to achieve this performance are rooted in change tracking, configuration management, and robust processes for hardware and particularly software delivery. Lessons learned from the initial startup of the AP1000 units have been incorporated into Westinghouse’s standard procedures for future new plants and for operating plants. Conclusion Westinghouse was able to deliver on the promise of digital I&C for the benefit of the AP1000 plants without experiencing the difficulties typically associated with large, complex I&C projects. This was achieved by leveraging the latest technologies and decades of lessons learned on processes, integration, testing and licensing. With the recent completions of the AP1000 plants in China, these digital I&C solutions can now be applied to further enhance our upgrade products for operating plants to realize all of the associated benefits including:  Reduced maintenance  Ease of operations  Superior diagnostic tools  Minimized operational risks Westinghouse will continue to evolve new digital I&C technologies for the benefit of new and operating plants as the nuclear industry continues to incorporate these more efficient technologies into their fleets. Ovation™ are trademarks or registered trademarks of Emerson Automation Solutions family of business units. Other names may be trademarks of their respective owners. Contact: Donna Ruff, Westinghouse Electric Company LLC, telephone: (412) 374-4705, email: ruffdl@westinghouse. com. Senior reactor operator training in the AP1000 Plant Simulator.