REACTOR POWER SET BACK MODULE

REACTOR POWER SET BACK MODULE – TOPICS DISCUSSED FEATURES DESIGN AND DEVELOPMENT TESTING DOCUMENTATION PHOTOGRAPHS

REACTOR POWER SET BACK MODULE – FEATURES It is a 5U width Safety Class 1A system developed to monitor complex reactor operation through several input contacts and linear power signal and takes necessary actions to inhibit Reactor Trip in case of occurrence of specified event i.e. Reactor Power Set Back (RPSB). It also enables or disables the Control and Safety Rod Drive Mechanism (CSRDM) operation used for driving control rods for addition of positive or negative reactivity during Reactor Power Set Back Operation. Module generates a complex sequence of contact outputs during RPSB operation, displays the Total RPSB Operation Time and the Remaining RPSB Operation Time in analog and digital form, outputs internally generated important Threshold Parameters and Linear Neutron Power signal for monitoring and remote transfer purpose. All the important Analog Parameters generated, Digital Delays incorporated in the design are completely settable for providing flexibility required during commissioning and operation. RPSB Module has Built In Test Feature i.e. is completely testable in the Test Mode w/o any external components. Accuracy of all the Analog and Digital Outputs is within ±1% of the Full Scale Output. Entire circuit design is FAIL-SAFE against Power Supply Failure and Logic Failure

REACTOR POWER SET BACK MODULE – DESIGN AND DEVELOPMENT The design developed is a complex mixed signal design using three separate multilayer PCBs with well defined functionalities such as Complex Logic Operation, Output Contact Generation, Front Panel Displays, Indications and Monitoring Jacks. Design with Minimum Components for Safety Class 1A system with complete functionality both in Operate and Test Mode. Entire design is Fail Safe. EMI/EMC filters, Spike Busters and Linear Regulators on the power supply line for better performance, lower CE and CS and Overvoltage protection. Decoupling Capacitors on P.S. Lines for all the Analog and Digital Components for better noise performance. Better Analog performance using Multilayer PCBs with separate ground plain. Proper Shielding against high frequency components such as clocks and DC to DC converters for lower RE, RS. CMOS design for adequate Noise Margin on Digital Lines for industrial application. Complete PSPICE Models generated and design verified before development. Development has been carried out as per approved Quality Acceptance Procedure (QAP) from Q.C. of the Client and Q.S. of Nuclear Power Corporation Of India Limited.

REACTOR POWER SET BACK MODULE – DESIGN AND DEVELOPMENT All Industrial Grade Components with temperature ranging from -40 degree C to +105 degree C or more. All the components chosen are latest in their production cycle with minimum chances of getting obsolete for the coming 10 years or more. All the industrial Components procured through international distributors / reputed manufacturers with Certificates of Compliance (COC) and Test Reports (TRs). All the procured components such as ICs, Diodes, Passive Components are tested in-house for functionality, values, leakage etc. with Component Inspection Reports (CIR) generated. Industrial Grade PCBs developed by highly reputed PCB Manufacturers with Quality Assurance Reports generated. Completely Assembled PCBs are Acrylic Coated as per MIL standard 46058C for protection against temperature and moisture. Usage Of Teflon Wires and Tapes for Module Wiring. RPSB Module developed using Anodized, Toughened Aluminum designed and developed to sustain channel level seismic tests. Testing of the development has been done using Latest Measuring Instruments from reputed manufacturers with updated Calibration Certificates.

REACTOR POWER SET BACK MODULE - TESTS RPSB Module is a Safety Class 1A system which has gone through all the requisite tests before accepting it as suitable for extremely critical reactor operations. The tests conducted successfully on the RPSB Module alone and in RPSB Channel are as follows:- 1. INITIAL TESTS and BURN-IN TEST Functional Test – 1 / FT – 1 which is pre-Burn In and it tests the complete functionality of the Module as per the Approved Test & Acceptance Procedure developed by TECHNID SOLUTIONs and thoroughly reviewed, verified and approved by the client(s). BURN-IN which is a 100 hours POWER ON of the Module to test the general durability of the electronic components used in the module, PCB Wiring and Complex Module Wiring health and Monitoring the module temperature through out the operation. Functional Test – 2 / FT – 2 which is post-Burn In and it tests the complete functionality of the Module as per the Approved Test & Acceptance Procedure developed by TECHNID SOLUTIONs and thoroughly reviewed, verified and approved by the client(s). Before and After BURN-IN tests, all the analog outputs were found to be well within limits. The digital outputs and all the field contacts generated from the module were monitored and found to be correct before and after the completion of BURN-IN tests.

REACTOR POWER SET BACK MODULE - TESTS 2. CLIMATIC TESTS A set of four tests have been conducted successfully under climatic tests which comprise of both dry and damp environment tests. The tests conducted were as follows: DRY COLD CYCLE TEST OF RPSB Module as per PFBR/60000/SP/1013, Rev.3.0. DRY HEAT CYCLE TEST OF RPSB Module as per PFBR/60000/SP/1013, Rev.3.0. TEMPERATURE CYCLE TEST OF RPSB Module as per PFBR/60000/SP/1013, Rev.3.0. DAMP HEAT CYCLE TEST OF RPSB Module as per PFBR/60000/SP/1013, Rev.3.0. All the analog outputs were found to be well within limits. The digital outputs and all the field contacts generated from the module were monitored and found to be correct after the completion of the above mentioned tests.

REACTOR POWER SET BACK MODULE - TESTS 3. SEISMIC TEST A set of tests have been conducted on all the 3 axes i.e. X, Y and Z axes successfully as per PFBR standard- PFBR 26030 DN 10000 RB. On each of the 3 axes, 5 OBEs are followed by 1 SSE conducted as per FRS of LCC in Control Building. After the Seismic test the RPSB Channel consisting of the RPSB Module was examined and found to be free from mechanical damages no loosening of parts was observed. The unit was then found to be meeting the Post Seismic Functional Test requirement.

REACTOR POWER SET BACK MODULE - TESTS 4. EMI / EMC TESTS Following tests had been conducted as per IP.No. PFBR/60000/SP/1014, Rev.0 and the RPSB Channel along with the Module passed the Safety Class A criteria in all: Conducted Emission Test as per CISPR 11, CLASS A, GROUP1(2004-06) on DC I/P P/S. Radiated Emission Test as per CISPR 11, CLASS A, GROUP1(2004-06). Electrostatic Discharge Test as per IEC 61000-4-2 Radiated Susceptibility Test as per IEC 61000-4-3 Electrical Fast Transient test as per IEC 61000-4-4 on DC I/P P/S Surge Test as per IEC 61000-4-5 on DC I/P P/S Conducted RF Test as per IEC 61000-4-5 on DC I/P P/S Ring Wave & Damped Oscillatory Wave Test as per IEC 61000-4-12 on DC I/P P/S.

REACTOR POWER SET BACK MODULE - DOCUMENTATION Following documents have been generated as complete Technology Know-How for the development which has laid a strong foundation for Development, Intermediate and Final Review, Test and Acceptance and Future Multiplication of the developed item. PCB Schematic Files PCB Gerber Files PCB Bill Of Material Module Bill OF Material Module General Arrangement Diagram Module Wiring Diagram Module Test and Acceptance Plan Module Instruction Manual

REACTOR POWER SET BACK MODULE – FRONT PANEL

REACTOR POWER SET BACK MODULE – BACK PANEL AND OVERALL

REACTOR POWER SET BACK MODULE – FUNCTIONAL TESTING

REACTOR POWER SET BACK MODULE – BURN-IN TESTING

REACTOR POWER SET BACK MODULE – TOP VIEW INSIDE Efficient Wire Bunching Completely Maintainable with Proper Space Minimum Front Panel Wiring due to Front Panel PCB.

REACTOR POWER SET BACK MODULE – PCBs PCBs Completely Testable Even during Power On

REACTOR POWER SET BACK MODULE – MODULE WIRING CLAMPS and Bunching for Vibration and Shock resistance

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