Microsoft PowerPoint - KNS 기술정보회의(070405)-김창회

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1 디지털계측제어계통의 PLC 설계방향 원자력연구소 김창회 -1-

2 Table of Contents 안전등급 PLC (POSAFE-Q) 특징 POSAFE-Q 제공모듈들 POSAFE-Q 설계기준 POSAFE-Q 설계방법및절차 POSAFE-Q 시험종류및절차 완제품제작과정 분석보고서 3자검증결과 TR 작성 결론 -2-

안전등급 PLC (FOSAFE-Q) 개발 1 단계 (01.7.1 04.6.30) Prototype 개발 H/W & S/W Spec. H/W & S/W Design Function & Performance Testing Qualification Testing 2 단계 (04.7.1 08.4.30) 완제품개발및인허가획득 H/W & S/W Redesign 3 rd Party Review Performance Testing Qualification Testing Licensing Design/Fab.

3 안전등급 PLC (FOSAFE-Q) 개발 1 단계 ( ) Prototype 개발 H/W & S/W Spec. H/W & S/W Design Function & Performance Testing Qualification Testing 2 단계 ( ) 완제품개발및인허가획득 H/W & S/W Redesign 3 rd Party Review Performance Testing Qualification Testing Licensing Design/Fab. (POSCON) Req./Spec./Test (KAERI) 3 rd Party Review SW V&V (KAERI) -3-

4 안전등급 PLC (POSAFE-Q) 특징 원전 Q-Class 기준에따라개발 (IEEE Std 기준만족 ) RPS, CPCS, ESF-CCS 에서요구하는응답시간만족 결정론적통신프로토콜적용으로통신망신뢰도증대 안전계통에서요구하는신뢰도를만족시키기위해설계단계에서신뢰도분석수행 다양한온-라인자가진단기능제공으로신뢰성증대및유지보수편리 (Loopback, Watchdog 등 ) 다양한통신기능제공으로모든안전계통구현편리 시뮬레이션기능제공으로안전계통프로그램개발용이 FMS Station Profibus-FMS up to 12Mbps pset Engineering Station Master Local Bus Extension #0 DP Master Station RS-232C Slave Local Bus Extension #1 Master Local Bus Extension #2 Redundant CPU & I/O Extension Profibus-DP up to 12Mbps Slave Local Bus Extension #7 DP Slav Station #0 #1 DP Slav Station #2 Open Architecture PLC -4-

HR-SDN Module Profibus-FMS Module ProfiNet Module EtherNet

5 POSAFE-Q 제공모듈들 (1/2) Processor Module CPU 단중화 Processor Module CPU 이중화 Processor Module Communication Module HR-SDL Module HR-SDN Module Profibus-FMS Module ProfiNet Module EtherNet Module x x 294mm (19 inch Standard) Redundant CPU Extend I/O -5-

6 POSAFE-Q 제공모듈들 (2/2) I/O Module Digital Input 24VDC, 48VDC 120VAC, 230VAC Digital Output 24VDC, 48VDC, 125VDC 110~220VAC Relay Output 특수모듈 Analog Input, Analog Output Pulse Counter Module RTD 모듈 TC 모듈 I/O Extension Module 엔지니어링도구 (pset) -6-

7 POSAFE-Q 설계기준 H/W Quality IEEE Std. Safety Class 1E Seismic Category 1 Quality Class 1 APR-1400 안전계통을위한 PLC 기능및성능만족 10CFR50, Appendix B QA 요건만족 EPRI TR 요건및사양만족 IEEE Std 설계기준만족 ( 통신, 소프트웨어 ) 새롭게개발된안전등급 PLC -7-

8 POSAFE-Q Overall Design Process PLC 요건 PLC 사양 H/W 개념설계 H/W 상세설계 H/W 제작 Integration And Test 완제품제작 S/W 요건 S/W 사양 S/W Coding Hardware/Software Co-Design 분석보고서 Component Test Integration Test System Test EQ Test Performance Test 3 자인증시험 Test Procedure -8-

9 POSAFE-Q H/W 개발절차 Prototype Prototype Design Design FMEA FMEA & component component failure failure rate rate analysis analysis Aging Aging Fabrication Fabrication Operability Operability and and PerformanceTest PerformanceTest Equipment Equipment Qualification Qualification Test Test End End Product Product -9-

10 POSAFE-Q S/W 개발절차 (1/2) S/W 개발계획및절차에따라개발 USNRC Reg. Guide IEEE Std Sructural development method 적용 Formal method based SRS/SDS (State Chart, SDL) S/W V&V 계획및절차에따라검증 USNRC Reg. Guide IEEE Std Independent reviewer KAERI 인허가과제 istec : RTOS, HR-SDL S/W 시험계획및절차에따라시험 Component test Integration test System test -10-

11 POSAFE-Q S/W 개발절차 (2/2) Developer Reviewer Editor Compiler Pset SRS -NL -FM - Fagan inspection -Formal V&V Linker SDS -NL -FM - Fagan inspection -Formal V&V Codes - Unit coding - Unit testing - Fagan inspection -Unit Testing Integration - Code Integ. - Integ. testing - Fagan inspection - Integ. Testing RT-OS (pcos) Agent CPU Module Drive Network Interface Comm. Module Firmware I/O Modules Traceability Completeness Consistency Correctness Safety -11-

12 Test Procedure Installation Test Factory Acceptance Test Manufacturing Tests Equipment Qualification System Test Integration Test Operability & Performance Test Manufacture & Project Phase Qualification Developing Phase Qualification Component Test Hardware Software Requirement & Specification Review -12-

13 Component Test 목적 : H/W 및 S/W component 기능 / 성능시험 시험항목 Hardware component Unit H/W modules Timer Amplifier circuit Watchdog timer circuit A/D and D/A convert circuit Loopback circuits LED circuits, etc. Software component Unit S/W subroutine (sub-functions) Black box Test : External check of the subroutine White box Test : Internal check of the subroutine - H/W Component - S/W Component -13-

14 Integration Test 목적 : H/W 및 S/W component 통합에따른기능 / 성능시험 시험항목 H/W Integration Test 단위 H/W circuit 통합에따른시험 S/W Integration Test S/W subroutine들의통합에따른시험 H/W and S/W Integration Test H/W와 S/W들의통합에따른시험 Processor Module과의통합시험 각모듈과 PM의통합에따른시험 - H/W + S/W Component - Integration with Processor Module -14-

15 System Test 목적 : 안전계통 Platform으로 PLC 기능 / 성능시험 시험항목 Response time test I/O capabilities test Memory capacity and data retention capability test HR-SDL performance test HR-SDN performance test Profibus-FMS performance test Error Handling capability test 시험범위 안전계통적용을위한모든구성 -15-

16 Equipment Qualification Test 목적 : Harsh Environment에서안전기능을수행할수있음을검증 시험항목 Aging Environmental Test Seismic Test EMI/RFI Test Surge Test 1E/Non 1E Isolation Test -16-

17 완제품제작 ICT 완제품 ( 개발 ) -17-

18 중요분석보고서 통신망 Deterministic 분석 대상 : HR-SDL, Profibus-FMS 내용 : NUREG/CR-6082 기준 전송시간분석 Data Packet 및 Token Packet 오류발생주기분석 Token Packet 오류발생시회복시간분석 결론 : 매 10ms 마다 250byte 데이터전송가능 RTOS 최적화분석 대상 : pcos 내용및결론 사용되지않는함수및변수 : 102 개삭제 무의미한구문 : 1 개삭제 비효율적인코드 : 32개수정 PLC H/W 신뢰도분석 PLC FMEA 분석 -18-

19 RTOS (pcos) & HR-SDL 3 rd Party Review (1/2) 목적 : 해외수출및국내원전적용을위한인허가확보 인증기관 : GRS istec (German) 검증방법 개발및 V&V 결과에따른 Consistency Check, Formal Check, Functional Check 수행 미해결문제목록 (List of Open Point) 를발행하여개발자가 LOP 에따라설계변경 -19-

20 RTOS (pcos) & HR-SDL 3 rd Party Review (2/2) 제출문건 : 24 종 설계문건 Design Req., Design Spec., Concept Report SRS, SDS, Source Code CT Plan/Procedure/Report, IT Plan/Procedure/Report V&V 문건 V&V Report for SRS, SDS, Safety Analysis Report 검증기준 IEEE IEC 검증완료 : RTOS : 24 개 LOPs HR-SDL: 15 개 LOPs -20-

Survey : Method 2 독일 /HilScher사현장실사 Survey of Product Development

21 상용등급인증 대상 : Profibus-FMS 방법 : COTS Dedication Methods 1&2,4 적용 Special Purpose Testing : Method 1 TTA, PNO 인증 Commercial Grade Survey : Method 2 독일 /HilScher사현장실사 Survey of Product Development Record Operating Experience Data : Method 4 Operating History Record 수집 -21-

22 TR 작성 특정기술주제보고서 안전등급제어기 (POSAFE-Q) 부록 1: IDiPS RPS 부록 2: IDiPS ESF-CCS 두산중공업주식회사포스콘주식회사한국원자력연구소 -22-

23 결론 POSAFE-Q? IEEE 개발방법만족 EPRI-TR 요건및사양만족 EPRI-TR 각요건항목만족성평가 : TR 부록에추가 POSAFE-Q 인허가적합성 개발및 V&V 문서 : 450 건 EQ 시험완료 RTOS, HR-SDL 3 rd Party Review 완료 Profibus-FMS 상용등급인증 통신망 Deterministic 분석보고서등각종분석보고서작성 운전이력확보 울진 1&2호기 CCMS 설치 : 2007년 8월 포항제철선제공장설치 : 2007년 6월 RCOPS 적용가능성분석중 -23-

24 -24-

example code are examined in this stage The low pressure pressurizer reactor trip module of the Plant Protection System was programmed as subject for

example code are examined in this stage The low pressure pressurizer reactor trip module of the Plant Protection System was programmed as subject for 2003 Development of the Software Generation Method using Model Driven Software Engineering Tool,,,,, Hoon-Seon Chang, Jae-Cheon Jung, Jae-Hack Kim Hee-Hwan Han, Do-Yeon Kim, Young-Woo Chang Wang Sik, Moon