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All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Applying Human Factors Evaluation and Design Guidance to a Nuclear Power Plant Digital Control System

The United States (U.S.) nuclear industry, like similar process control industries, has moved toward upgrading its control rooms. The upgraded control rooms typically feature digital control system (DCS) displays embedded in the panels. These displays gather information from the system and represent that information on a single display surface. In this manner, the DCS combines many previously separate analog indicators and controls into a single digital display, whereby the operators can toggle between multiple windows to monitor and control different aspects of the plant. The design of the DCS depends on the function of the system it monitors, but revolves around presenting the information most germane to an operator at any point in time. DCSs require a carefully designed human system interface. This report centers on redesigning existing DCS displays for an example chemical volume control system (CVCS) at a U.S. nuclear power plant. The crucial nature of the CVCS, which controls coolant levels and boration in the primary system, requires a thorough human factors evaluation of its supporting DCS. The initial digital controls being developed for the DCSs tend to directly mimic the former analog controls. There are, however, unique operator interactions with a digital vs. analog interface, and the differences have not always been carefully factored in the translation of an analog interface to a replacement DCS. To ensure safety, efficiency, and usability of the emerging DCSs, a human factors usability evaluation was conducted on a CVCS DCS currently being used and refined at an existing U.S. nuclear power plant. Subject matter experts from process control engineering, software development, and human factors evaluated the DCS displays to document potential usability issues and propose design recommendations. The evaluation yielded 167 potential usability issues with the DCS. These issues should not be considered operator performance problems but rather opportunities identified by experts to improve upon the design of the DCS. A set of nine design recommendations was developed to address these potential issues. The design principles addressed the following areas: (1) color, (2) pop-up window structure, (3) navigation, (4) alarms, (5) process control diagram, (6) gestalt grouping, (7) typography, (8) terminology, and (9) data entry. Visuals illustrating the improved DCS displays accompany the design recommendations. These nine design principles serve as the starting point to a planned general DCS style guide that can be used across the U.S. nuclear industry to aid in the future design of effective DCS interfaces.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Fuzzy Controllers in the Adaptive Control System of a CNC Lathe

Traditional approaches to improving the technological system of CNC metal-cutting machines include increasing the rigidity, periodic maintenance and repair of its components, and operating at lower speeds. In practice, the most economical approach is stabilization of the inputs to the system. The development of adaptive control systems with stabilization of the cutting forces improves the precision and quality of machining in CNC metal-cutting machines, the productivity, and tool life. However, classical PID controllers are only effective in stabilizing the cutting forces in such systems if continuous real-time parameter adjustment is possible. That sharply increases the complexity of the controller. A new mathematical apparatus based on artificial intelligence (including fuzzy logic) permits the solution of adaptive control problems that previously could hardly even be formulated. The present work addresses the use of fuzzy logic in automatic stabilization of the cutting force for CNC lathes. Simulation of a fuzzy controller shows that this approach to automatic stabilization of the cutting force increases the machining efficiency on existing equipment with indeterminacy in the characteristics of the cutting system and the working environment.

42 ENGINEERING↗
DOE OSTI2017

Nuclear power plant risk-informed surveillance frequency control program implementation at the Duke Catawba nuclear plant with a focus on instrumentation and control systems - 333

This paper summarizes an updated process for risk-informed surveillance frequency control program (SFCP) implementation at the Catawba Nuclear Power Plant in the past year. This program includes selection and prioritization of specific target surveillance test interval extensions; and development, review, and implementation of surveillance test risk informed documented evaluation (STRIDE) packages designed to support extension of conventional surveillance requirement test intervals, in accordance with 'Risk-Informed Technical Specifications Initiative 5b, Risk-Informed Method for Control of Surveillance Frequencies, Industry Guideline,' NEI 04-10, Revision 1 . The scope of work associated with STRIDE development includes probabilistic risk assessment (PRA) case studies, deterministic assessment (DA) evaluations, and, where required, instrument drift evaluation (IDE). The STRIDE implementation efforts have also included support of independent decision-making panel (IDP) meetings at the implementing power stations and IDP member training. The purpose of this paper is to provide a presentation of a refined process for STRIDE development with a focus on instrumentation and control systems based on author experience, which includes support for the development of multiple STRIDE packages for the Catawba Nuclear Plant. This paper outlines a framework for practical implementation of an SFCP within the context of an integrated risk-informed performance-based regulation application program with emphasis on instrumentation and control systems. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Common Cause Failure Evaluation of High Safety-significant Safety-related Digital Instrumentation and Control Systems

Digital instrumentation and control (DI&C) systems in nuclear power plants (NPPs) have many advantages over analog systems but also pose different engineering and technical challenges, such as potential threats due to common cause failures (CCFs). This paper proposes a Platform for Risk Assessment of DI&C (PRADIC) developed by Idaho National Laboratory for dealing with potential software CCFs in DI&C systems of NPPs. The methodology development of PRADIC on the quantitative evaluation of software CCFs in high safety-significant safety-related DI&C systems in NPPs is illustrated in this paper. In PRADIC, qualitative hazard analysis and quantitative reliability and consequence analysis are successively implemented to obtain quantitative risk information, compare with respective risk evaluation acceptance criteria, and provide suggestions for risk reduction and design optimization. A comprehensive case study was also performed and documented in this paper. Results show that PRADIC can effectively identify potential digital-based CCFs, estimate their failure probabilities, and evaluate their impacts to system and plant safety.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

High density, multi-range analog output Versa Module Europa board for control system applications

A new VMEDAC64, 12-bit 64 channel digital-to-analog converter, a Versa Module Europa (VME) module, features 64 analog voltage outputs with user selectable multiple ranges, has been developed for control system applications at Inter University Accelerator Centre. The FPGA (Field Programmable Gate Array) is the module's core, i.e., it implements the DAC control logic and complexity of VMEbus slave interface logic. The VMEbus slave interface and DAC control logic are completely designed and implemented on a single FPGA chip to achieve high density of 64 channels in a single width VME module and will reduce the module count in the control system applications, and hence will reduce the power consumption and cost of overall system. One of our early design goals was to develop the VME interface such that it can be easily integrated with the peripheral devices and satisfy the timing specifications of VME standard. The modular design of this module reduces the amount of time required to develop other custom modules for control system. The VME slave interface is written as a single component inside FPGA which will be used as a basic building block for any VMEbus interface project. The module offers multiple output voltage ranges depending upon the requirement. The output voltage range can be reduced or expanded by writing range selection bits in the control register. The module has programmable refresh rate and by default hold capacitors in the sample and hold circuit for each channel are charged periodically every 7.040 ms (i.e., update frequency 284 Hz). Each channel has software controlled output switch which disconnects analog output from the field. The modularity in the firmware design on FPGA makes the debugging very easy. On-board DC/DC converters are incorporated for isolated power supply for the analog section of the board.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

History of Industrial Control System Cyber Incidents

For many years malicious cyber actors have been targeting the industrial control systems (ICS) that manage our critical infrastructures. Most of these events are not reported to the public, and the threats and incidents to ICS are not as well-known as enterprise cyber threats and incidents. This paper is a brief study of publically reported cyber threats to critical infrastructure that sheds light on the growing cyber threats to ICS devices. It is important to note that this list is not all inclusive. The events selected in this study highlight the significant threats and incidents to industrial control systems and demonstrate that significant cyber incidents to ICS devices are growing and becoming more complex.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

The Fermilab SSR1 and HB650 Synoptic and EPICS remote cryogenic control system

The 325MHz Single Spoke Resonator 1 (SSR1) Cryomodule (CM) has a 5.3-meter length, and it has 288-liter liquid helium @ 4.5K mode. The High Beta 650 MHz (HB650) CM contains six elliptical cavity cryomodules, has a 9.9-meter overall length and it has 530-liter liquid helium. The SSR1 and HB650 CM had been tested at Fermilab Cryomodule Test Facility (CMTF). Their cryogenic control system includes the Siemens Process Control System S7-400, Automation Direct DL205 PLC, and remote synoptic HMI/EPICS Phoebus GUI. This paper presents a method which has been successfully used by Fermilab PIP2 IT cryogenic remote on-line, real-time control systems.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2012

Dynamic characteristics of an orthogonal turbine and output-control systems for TPP with high-voltage frequency converter

A mathematical description of a closed control system with allowance for pressure fluctuations in the head system, which makes it possible to analyze the regime stability of orthogonal generating sets at tidal electric power plants when operating in the complete range of heads, outputs, and rotational speeds, and to select parameters of the control system, is obtained for an orthogonal hydroturbine and a generator with a load regulator.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Remote optical wind detection and aerodynamic control system for ground vehicle

An aerodynamic control system for a ground vehicle comprises a LiDAR module including at least one LiDAR sensor configured to obtain wind data upstream of the ground vehicle; a computing device; an aerodynamic device controller; and an aerodynamic device including a control surface. The computing device is configured to receive the wind data from the LiDAR module and generate output signals based on the wind data. The aerodynamic device controller is configured to receive the output signals from the computing device and generate control signals to control the aerodynamic device to adjust aerodynamic properties of the ground vehicle based at least in part the wind data. Changes to the configuration of the control surface may include increasing or decreasing a deflection angle of the at least one aerodynamic device. The aerodynamic device may include, e.g., a pneumatically actuated aerodynamic device or an electro-mechanically actuated aerodynamic device.

Damon, Kenneth H.↗
DOE OSTI2019

Energy-Efficient Actuator for the Control System of Promising Vehicles

A mathematical model is developed to describe the energy-efficient actuator of control systems for promising autonomous vehicles (drones, torpedoes, etc.) with different current sources. The energy and dynamic characteristics of control systems with different power supplies are compared.

42 ENGINEERING↗
DOE OSTI2014

Simple adaptive control system design for a quadrotor with an internal PFC

The paper deals with an adaptive control system design problem for a four rotor helicopter or quadrotor. A simple adaptive control design scheme with a parallel feedforward compensator (PFC) in the internal loop of the considered quadrotor will be proposed based on the backstepping strategy. As is well known, the backstepping control strategy is one of the advanced control strategy for nonlinear systems. However, the control algorithm will become complex if the system has higher order relative degrees. We will show that one can skip some design steps of the backstepping method by introducing a PFC in the inner loop of the considered quadrotor, so that the structure of the obtained controller will be simplified and a high gain based adaptive feedback control system will be designed. The effectiveness of the proposed method will be confirmed through numerical simulations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2013

A reliable control system for measurement on film thickness in copper chemical mechanical planarization system

In recent years, a variety of film thickness measurement techniques for copper chemical mechanical planarization (CMP) are subsequently proposed. In this paper, the eddy-current technique is used. In the control system of the CMP tool developed in the State Key Laboratory of Tribology, there are in situ module and off-line module for measurement subsystem. The in situ module can get the thickness of copper film on wafer surface in real time, and accurately judge when the CMP process should stop. This is called end-point detection. The off-line module is used for multi-points measurement after CMP process, in order to know the thickness of remained copper film. The whole control system is structured with two levels, and the physical connection between the upper and the lower is achieved by the industrial Ethernet. The process flow includes calibration and measurement, and there are different algorithms for two modules. In the process of software development, C++ is chosen as the programming language, in combination with Qt OpenSource to design two modules’ GUI and OPC technology to implement the communication between the two levels. In addition, the drawing function is developed relying on Matlab, enriching the software functions of the off-line module. The result shows that the control system is running stably after repeated tests and practical operations for a long time.

42 ENGINEERING↗
DOE OSTI2013

Model predictive control system and method for integrated gasification combined cycle power generation

Control system and method for controlling an integrated gasification combined cycle (IGCC) plant are provided. The system may include a controller coupled to a dynamic model of the plant to process a prediction of plant performance and determine a control strategy for the IGCC plant over a time horizon subject to plant constraints. The control strategy may include control functionality to meet a tracking objective and control functionality to meet an optimization objective. The control strategy may be configured to prioritize the tracking objective over the optimization objective based on a coordinate transformation, such as an orthogonal or quasi-orthogonal projection. A plurality of plant control knobs may be set in accordance with the control strategy to generate a sequence of coordinated multivariable control inputs to meet the tracking objective and the optimization objective subject to the prioritization resulting from the coordinate transformation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

An Agile/XP software development process for modernizing the accelerator control system at Fermilab

Fermilab is undergoing the most ambitious upgrade to its accelerator control system of the 21st century. As part of the ACORN project, hundreds of legacy control system applications written in C/C++ will be re-imagined and developed from the ground up. In addition, applications to support Fermilab’s new super-conducting linear accelerator are already under construction. To manage the development of modern controls applications, the Controls department has adopted an Agile software development process based on eXtreme Programming. In this paper we will describe our process and detail our experience applying it to the development of two case studies.

Diamond, John [Fermilab]↗
DOE OSTI2014

Development of an Automated Decision-Making Tool for Supervisory Control System

This technical report was generated as a product of the Supervisory Control for Multi-Modular Small Modular Reactor (SMR) Plants project within the Instrumentation, Control and Human-Machine Interface technology area under the Advanced Small Modular Reactor (AdvSMR) Research and Development Program of the US Department of Energy. The report documents the definition of strategies, functional elements, and the structural architecture of a supervisory control system for multi-modular AdvSMR plants. This research activity advances the state of the art by incorporating real-time, probabilistic-based decision-making into the supervisory control system architectural layers through the introduction of a tiered-plant system approach. The report provides background information on the state of the art of automated decision-making, including the description of existing methodologies. It then presents a description of a generalized decision-making framework, upon which the supervisory control decision-making algorithm is based. The probabilistic portion of automated decision-making is demonstrated through a simple hydraulic loop example.

42 ENGINEERING↗
DOE OSTI2024

ML based control systems for nuclear physics experiments

The Experimental Physics Software and Computing Infrastructure (EPSCI) group at Jefferson Lab is leading the use of machine learning (ML) to enhance control systems in nuclear physics experiments. Collaborating closely with domain experts and data scientists, we have developed an ML-based control system that uses a Gaussian process to dynamically adjust the high voltage of the GlueX Central Drift Chamber. This results in stable detector performance by adapting to environmental changes, thereby reducing the offline calibration effort. Furthermore, we are developing ML-driven systems for optimizing the polarization of photon beams and polarized cryotargets. These systems will maintain the optimal microwave frequency in cryogenic targets and make real-time adjustments to diamond radiators for polarized photon sources, tasks traditionally handled by human operators. By automating these functions, we aim to optimize the polarization, reduce downtime, and minimize human error. This talk will highlight the development of reliable ML-based control systems and the policies to ensure they are both effective and trustworthy.

Jeske, Torri↗
DOE OSTI2023

Maximum-impact Adversary Design for Network-based Control System: A Case Study on Grid-interactive Efficient Buildings

The Internet of Things (IoT) technology has dramatically improved the efficiency of today's building operation and management. By connecting controllable devices into a communication network, control signals can be easily passed to the devices, and operating status can be acquired from measurable ends with minimal effort. However, this all-connected configuration could also expose the network-based control system (NBCS) to malicious actions, such as cyberattacks. One of the common NBCSs is the building automation system. With the promotion of grid-interactive efficient buildings (GEBs), there has been increasing attention on securing the buildings from the network perspective. This research proposes a maximum-impact adversary design framework so that the adversary can provide the most adversarial impact on the controlled system while remaining stealthy. The proposed framework is numerically demonstrated on a network-based building energy and control system. The building energy system is built in a Modelica-based simulation environment and controlled by the state-of-the-art ASHRAE Guideline 36 control sequences. The control commands at the supervisory level, generated from the Guideline 36 controller, are assumed to be sent to local devices through communication networks using the BACnet protocol. Simulation results show that the proposed maximum-impact adversary on such a system can stealthily affect the building system's performance to its maximum extent. It is anticipated that results can be used by researchers and practitioners in the building automation industry to design efficient and robust cyber-attack detection algorithms, especially for stealthy attacks.

Chu, Mengyuan↗