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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Utility and Industry Perceptions of Control Room Modernization Over the Last 10 Years

Within the current United States (U.S.) nuclear power fleet, main control room modernization (CRM) is an important step towards cost savings. In recent decades, plants have been engaged in upgrades to varying degrees. This process requires a nuanced, balanced, and timely approach that ensures continued safety and long-term sustainability. In 2012 a survey was issued to individuals from the nuclear industry to learn their perspectives on a range of CRM issues. The survey targeted the benefits and challenges for utilities undertaking this process, including the main drivers and barriers to technology upgrades, regulatory compliance, and the effects these factors have on concepts of operations, strategic approaches, and staffing. In 2022, the survey was issued again to understand whether CRM perceptions had changed in the last 10 years. Our findings identify changes in industry thinking from a decade ago. Here we reveal perspective shifts that represent increased optimism and, in some instances, increased doubt regarding the opportunities and challenges inherent in CRM and implementation. We also report nuanced differences in CRM perspectives between utility and surrounding nuclear industry respondents.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

The evolution of the Human Systems and Simulation Laboratory in nuclear power research

The events at Three Mile Island in the United States brought about fundamental changes in the ways that simulation would be used in nuclear operations. The need for research simulators was identified to scientifically study human-centered risk and make recommendations for process control system designs. This paper documents the human factors research conducted at the Human Systems and Simulation Laboratory (HSSL) since its inception in 2010 at Idaho National Laboratory. The facility’s primary purposes are to provide support to utilities for system upgrades and to validate modernized control room concepts. In the last decade, however, as nuclear industry needs have evolved, so too have the purposes of the HSSL. Thus, beyond control room modernization, human factors researchers have evaluated the security of nuclear infrastructure from cyber adversaries and evaluated human-in-the-loop simulations for joint operations with an integrated hydrogen generation plant. Lastly, our review presents research using human reliability analysis techniques with data collected from HSSL-based studies and concludes with potential future directions for the HSSL, including severe accident management and advanced control room technologies.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Method to Investigate Cognitive Aging Effects in Nuclear Operations Using the Rancor Microworld Simulator

Many nuclear power plant (NPP) operators are close to, or at retirement age. Since NPP operators are responsible for tasks that engage different and complex cognitive abilities, human factors researchers recently called for the need to examine cognitive aging effects and potential interactions with modernized control rooms. One way control rooms are being modernized is by replacing paper-based procedures with computer-based procedures (CBPs). This paper outlines a method for testing preference and usability of three types of CBPs as a function of age, in simulated NPP operations. The Rancor Microworld Simulator will be used, which mimics an NPP control room, allowing novices to learn to perform operator tasks quickly. The experiment will have two independent variables: age (young and old) and CBP-type (Type 1, Type 2, and Type 3). The three types of CBPs vary in levels of embedded instrumentation and controls. Adults aged 18–25 years (young group) and =60 years (older group) will be recruited from the general population. The dependent variables will be preference and usability metrics via survey and simulator logs. All participants will perform two scenario types (startup and loss of feedwater operations) and will be randomly assigned to one type of CBP to guide them through the scenario. Analyses of variance (ANOVAs) will be used to determine whether there is a main effect of age and any age x CBP-type interactions on the preference and usability dependent variables.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Human and Technology Integration Evaluation of Advanced Automation and Data Visualization

While the existing United States (U.S.) light water reactors are highly reliable, safe, and provide a significant proportion of carbon-free electricity, the cost of operating and maintaining them has become less competitive compared to other electricity generating sources. The reason for the gap in operating and maintenance (O&M) costs can be at least in part attributed to the advent of new digital technologies that other electricity generating industries are currently using. Advanced capabilities including digital instrumentation and control (I&C) systems, advanced automation and analytics, and greater span of data integration (i.e., connectedness) across these non-nuclear plants has transformed the way work is performed and ultimately given them a competitive advantage in terms of the cost required for operating, maintaining, and supporting them. To reduce O&M cost and address obsolescence of the aging I&C infrastructure of the existing U.S. light water reactors, the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program Plant Modernization Pathway is conducting targeting multidisciplinary research that 1) delivers a sustainable business model to enable a cost-competitive U.S. nuclear industry and 2) is developing technology modernization solutions that address aging and obsolescence challenges. The work described in this report supports these two objectives and describes the demonstration of human and technology integration across recent industry collaborations to support their large-scale digital I&C modifications. This technical report describes the demonstration of the human and technology integration methodology in performing full-scale performance-based human-in-the-loop tests to evaluate plant-specific advanced automation and data visualization applications within these collaborators’ digital modifications. This technical report also documents future applications of human and technology integration that expand beyond main control room modernization and digital I&C upgrades, which have been a central focus to date. Thus, this technical report discusses how to implement human and technology integration across new business opportunities and how to develop an evaluation plan that defines measures and criteria, and documents key assumptions to support full plant modernization.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Demonstration of the Human and Technology Integration Guidance for the Design of Plant-Specific Advanced Automation and Data Visualization Techniques

Nuclear power continues to be a safe, reliable, and carbon-free electricity generating source for the United States, though the cost of operating and maintaining the current United States nuclear power plant fleet has become uncompetitive with other sources. This gap is attributed to the advent of new digital instrumentation and control technologies that other electricity generating industries are currently leveraging to streamline work and greatly reduce operating, maintenance, and support costs. Digital instrumentation and control systems and control room modernization offers significant opportunities to reduce operating and maintenance costs to ensure the continued operation of the existing United States light-water reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Demonstration and Evaluation of the Human-Technology Integration Guidance for Plant Modernization

The significance of nuclear power in its role producing carbon-free electricity to the U.S. cannot be overstated. However, with changes in the energy market coupled with changes in incentives given to certain resources like solar and wind, the operating and maintenance costs for these sources have seen a significant reduction, which has consequently negatively impacted the economic viability of the existing U.S. nuclear power plant fleet. Digital instrumentation and control (I&C) and control room modernization is a major critical work domain to reduce operating and maintenance costs. Existing nuclear power plants are commonly configured with mostly legacy analog I&C as well as isolated pockets of digital I&C (a plant process computer, digital recorders, etc.). One challenge with this analog I&C is that replacement parts are becoming prohibitively more expensive and difficult to obtain. Moreover, a significant challenge with the existing analog I&C is that the way in which plants are currently operated and maintained is no longer competitive with other electricity generating sources, like natural gas, where advanced digital I&C technologies are commonplace. This gap between the waynuclear power plants are operated compared to other electricity generating sources significantly challenges the economic viability of the nuclear industry. Indeed, digital I&C systems can fundamentally change the way the plant is operated (i.e., the concept of operation). The introduction of digital I&C technologies offers a wealth of benefits to the nuclear industry. However, it is important to emphasize that, to realize these benefits, a careful understanding of how to integrate technology in a collaborative way that leverages the capabilities of people and technologies is necessary. Human-technology integration applies human factors engineering methods and tools to ensure the safe and reliable use of these technologies while ensuring that the inherent features of the technologies that provide economic value are not missed. The scope of this work documents the demonstration of the recently developed human and technology integration methodology, as applied to developing a new vision and concept of operations for a major U.S. nuclear power plant fleet. This report focuses on the methodological aspects of developing a vision and concept of operations. This report shares the tools, activities, and lessons learned during a modernization currently underway for industry as a whole to consider when planning any significant digital modification and developing a new vision and concept of operations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Cognitive Aging as a Human Factor: Effects of Age on Human Performance

Nuclear power plant (NPP) control room operators must make ongoing computations and decisions that maximize production and ensure safety, which places a high cognitive burden on the operators. How cognitions such as attention, visuospatial ability, and working memory interact with socio-technical systems to achieve optimal operations is well studied. However, there is an absence of research that examines how cognitive functioning within the NPP control room environment is moderated by developmental aging processes. This is of critical importance because different types of cognitive actions are known to develop and peak at different times across the adult life span, and it is becoming increasingly clear that there is no age at which all cognitive faculties operate at maximum capacity. Thus, given that NPPs are experiencing an aging workforce, it is vital to identify how mission critical cognitions change with age. This paper reviews implications of aging on reactor operators in the current and new fleet. We highlight lessons that can be learned from state-of-the-art human factors research that considers aging, lessons from the large cognitive aging literature, and lessons from aging workers in other industries that use sophisticated socio-technical systems, such as aviation. We also consider the important subject of aging effects versus expertise and present preliminary data that support the premise that age of operator is linked to effective and efficient operations but that this relationship may be moderated by level of operations expertise. In conclusion, we apply these lessons to future considerations for aging research in current nuclear operations and with the advent of advanced modernized control rooms.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Rancor-HUNTER: A Virtual Plant and Operator Environment for Predicting Human Performance

Advances in simulation capabilities to model physical systems have outpaced the development of simulations for humans using those physical systems. There is an argument that the infinite span of potential human behaviors inherently render human modeling more challenging than physical systems. Despite this challenge, the need for modeling humans interacting with these complex systems is paramount. As technologies have improved, many of the failure modes originating from the physical systems have been solved. This means the overall proportion of human errors has increased, such that it is not uncommon to be the primary driver of system failure in modern complex systems. Moreover, technologies such as automated systems may introduce emerging contexts that can cause new, unanticipated modes of human error. Therefore, it is now more important than ever to develop models of human behavior to realize overall system error reductions and achieve established safety margins. To support new and novel concepts of operations for the anticipated wave of advanced nuclear reactor deployments, human factors and human reliability analysis researchers need to develop advanced simulation-based approaches. This talk presents a simulation environment suitable to both collect data and then perform Monte Carlo simulations to evaluate human performance and develop better models of human behavior. Specifically, the Rancor Microworld Simulator models a complex energy production system in a simplified manner. Rancor includes computer-based procedures, which serve as a framework to automatically classify human behaviors without manual, subjective experimenter coding during scenarios. This method supports a detailed level of analysis at the task level. It is feasible for collecting large sample sizes required to develop quantitative modelling elements that have historically challenged traditional full-scope simulator study approaches. Additionally, the other portion of this experimental platform, the Human Unimodel for Nuclear Technology to Enhance Reliability (HUNTER), is presented to show how the collected data can be used to evaluate novel scenarios based on the contextual factors, or performance shaping factors, derived from Rancor simulations. Rancor-HUNTER is being used to predict operator performance with new procedures, such as results from control room modernization or new-build situations. Rancor-HUNTER is also proving a useful surrogate platform to model human performance for other complex systems.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS1993

WTEC monograph on instrumentation, control and safety systems of Canadian nuclear facilities

This report updates a 1989-90 survey of advanced instrumentation and controls (I&C) technologies and associated human factors issues in the U.S. and Canadian nuclear industries carried out by a team from Oak Ridge National Laboratory (Carter and Uhrig 1990). The authors found that the most advanced I&C systems are in the Canadian CANDU plants, where the newest plant (Darlington) has digital systems in almost 100 percent of its control systems and in over 70 percent of its plant protection system. Increased emphasis on human factors and cognitive science in modern control rooms has resulted in a reduced workload for the operators and the elimination of many human errors. Automation implemented through digital instrumentation and control is effectively changing the role of the operator to that of a systems manager. The hypothesis that properly introducing digital systems increases safety is supported by the Canadian experience. The performance of these digital systems has been achieved using appropriate quality assurance programs for both hardware and software development. Recent regulatory authority review of the development of safety-critical software has resulted in the creation of isolated software modules with well defined interfaces and more formal structure in the software generation. The ability of digital systems to detect impending failures and initiate a fail-safe action is a significant safety issue that should be of special interest to nuclear utilities and regulatory authorities around the world.

Uhrig, Robert E.↗
DOE OSTI2024

Human Factors Challenges in Modernizing Nuclear Power Plant Control Rooms

Jeffrey Joe has been invited to give a presentation entitled, “Human Factors Challenges in Modernizing Nuclear Power Plant Control Rooms,” at the 2024 Human Systems Symposium. Experts conducting human factors and human systems research will gather and share research at this conference. This conference is a good opportunity to develop new business for INL via research collaborations, as attendees exchange knowledge and explore the latest trends, advancements, and challenges in the field of human systems research across the DOE national laboratories.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Safety-Related Instrumentation and Control Upgrade Pilot Project: NUREG- 0711 Process Development, Planning and Analysis Activities, and Lessons Learned

Constellation Energy and the United States Department of Energy (DOE) have established a public/private partnership to implement a pilot digital upgrade to replace legacy analog, safety-related reactor protection and emergency safety feature actuation systems (RPS/ESFAS) with modern digital systems. This effort is occurring at Constellation’s Limerick Generating Station. This project is being performed in accordance with industry processes that have been adapted to better support digital upgrades. These processes include IP-ENG-001, Standard Design Process, NISP-EN-04, Standard Digital Engineering Process and Electric Power Research Institute Report 3002011816, Digital Engineering Guide. The Light Water Reactor Sustainability (LWRS) Program at the Idaho National Laboratory (INL) has been supporting this effort. Latest INL HFE efforts in support of this project have focused on definition and implementation of the Human Factors Engineering (HFE) Program in support of Constellation design and related licensing efforts. This paper presents the development execution of the HFE Program through completion of the Planning and Analysis Phase as defined by NUREG-0711 as well as HFE lessons learned.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Evaluation of color in digital nuclear power plant control room displays

Human system interface design in industrial process control is guided by industry standards, human factors best practices, and domain-specific conventions, and often there is a conflict between one or more of the sources of design input for specific design elements. In the nuclear domain, one design element for which conflict arises is the use of color to represent equipment state. Here, this study evaluates the tradeoffs associated with using color in a process control display versus using white and shades of gray. The performance metrics were response time, accuracy, and eye movement metrics using a simplified experimental task and professional operators. Results revealed that adhering to color conventions in nuclear power yielded small advantages in simple tasks, but did not exist for more complex tasks. The results did not provide strong evidence for or against using a particular color scheme and revealed the need for further research on the use of color for commercial nuclear power plants and other process control industries.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Design Philosophy for Accelerator Control Rooms

This report describes the foundational human factors principles needed to design user interfaces for accelerator control rooms. These principles are presented as recommendations for accelerator control system interface design and are illustrated with examples drawn from accelerator operations at Fermi National Accelerator Laboratory (Fermilab). These high-level principles are intended to serve as design objectives that apply generally across all control system interfaces developed for the accelerator complex. This design philosophy document is a high-level roadmap to approach the general interface design for the accelerator complex. This philosophy applies state-of-the-art human factors principles and evidence-based design standards to an accelerator environment, which will transform the next era of accelerator interfaces as outlined by the Accelerator Controls Operations Research Network (ACORN) Project. Further work will include mapping the general design principles included in this report to more specific guidance in the form of a user interface style guide.

43 PARTICLE ACCELERATORS↗
NASA NTRS1997

Scale Model Icing Research Tunnel

NASA Lewis Research Center's Icing Research Tunnel (IRT) is the world's largest refrigerated wind tunnel and one of only three icing wind tunnel facilities in the United States. The IRT was constructed in the 1940's and has been operated continually since it was built. In this facility, natural icing conditions are duplicated to test the effects of inflight icing on actual aircraft components as well as on models of airplanes and helicopters. IRT tests have been used successfully to reduce flight test hours for the certification of ice-detection instrumentation and ice protection systems. To ensure that the IRT will remain the world's premier icing facility well into the next century, Lewis is making some renovations and is planning others. These improvements include modernizing the control room, replacing the fan blades with new ones to increase the test section maximum velocity to 430 mph, installing new spray bars to increase the size and uniformity of the artificial icing cloud, and replacing the facility heat exchanger. Most of the improvements will have a first-order effect on the IRT's airflow quality. To help us understand these effects and evaluate potential improvements to the flow characteristics of the IRT, we built a modular 1/10th-scale aerodynamic model of the facility. This closed-loop scale-model pilot tunnel was fabricated onsite in the various shops of Lewis' Fabrication Support Division. The tunnel's rectangular sections are composed of acrylic walls supported by an aluminum angle framework. Its turning vanes are made of tubing machined to the contour of the IRT turning vanes. The fan leg of the tunnel, which transitions from rectangular to circular and back to rectangular cross sections, is fabricated of fiberglass sections. The contraction section of the tunnel is constructed from sheet aluminum. A 12-bladed aluminum fan is coupled to a turbine powered by high-pressure air capable of driving the maximum test section velocity to 550 ft/sec (Mach 0.45). The air turbine and instrumentation are housed inside a fiberglass nacelle. Total and static pressure measurements can be taken around the loop, and velocity and flow angularity measurements can be taken with hot-wire and five-hole probes at specific locations. The Scale Model Icing Research Tunnel (SMIRT) is undergoing checkout tests to determine how its airflow characteristics compare with the IRT. Near-term uses for this scale-model tunnel include determining the aerodynamic effects of replacing the 52-yearold W-shaped heat exchanger with a flat-faced heat exchanger. SMIRT is an integral part of the improvements planned for the IRT because testing the proposed IRT improvements in a scale-model tunnel will lower costs and improve productivity.

Canacci, Victor A.↗
DOE OSTI2023

DEMONSTRATION OF A MULTI-STAGE TESTING AND EVALUATION APPROACH FOR A SAFETY-RELATED DIGITAL UPGRADE AT A NUCLEAR POWER PLANT

There is an imminent need for existing United States nuclear power plants to reduce their operating and maintenance costs to remain economically viable. Digital technology provides significant opportunity for the existing nuclear power plant fleet to transform that way in which work is accomplished to reduce costs and allow the fleet to remain economically competitive. However, a careful understanding of the human-technology integration is needed to ensure the continued safe and reliable operation of these existing plants with new digital capabilities. This work presents interim findings in applying human factors engineering to a safety-significant digital upgrade for a United States nuclear power plant, following the new Alternative Review Process in the recently revised Digital Instrumentation and Control Interim Staff Guidance Licensing Process, Revision 2. The interim results described in this work provides an industry perspective, based on ongoing work, to recent work published from Vazquez, Green, and Desaulniers (2022).

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Bridging the Gap Between Modern UX Design and Particle Accelerator Control Room Interfaces

Accelerator control systems often represent relatively complex and safety-sensitive human-machine interfaces within process control industries. These systems are technically robust and reflect the cumulative integration of solutions built and adapted across decades. One of the regular, unfortunate casualties of provisional accelerator control system updates is their human-system interfaces (HSIs) which often lag behind modern usability and design standards. An additional challenge is that although there is a multitude of established human factors (HF), and user experience (UX) principles for everyday digital applications, there are very few (if any) established principles for complex and safety-critical applications for an accelerator. This paper argues for the importance of established HF and UX principles (herein referred to as human-centered design principles) into the development of accelerator HSIs, emphasizing the need for clarity, consistency, responsiveness, and cognitive accessibility. Drawing from HF/UX best practices and human-centered design, this paper discusses how these approaches can enhance operator performance, reduce human error, and improve accelerator personnel collaboration. Case studies from Accelerator Control Operations Research Network (ACORN) at Fermilab are explored to demonstrate how interfaces built with human-centered design principles can scale with system complexity while remaining intuitive and efficient for diverse user roles including operators, machine experts, and engineers. By bridging the gap between traditional control system design and modern human-centered design methods, this paper provides a roadmap for evolving accelerator HSIs into more usable, maintainable, and effective tools.

Hill, Rachael [Idaho Natl. Lab.]↗