Above: A programme of works will extend the life of Kozloduy units 5 and 6 and will see the plant operate for at least 60 years Source: Radiy-Radics
programme of works undertaken by RPC Radiy and Radics LLC, the subsequent successful launch of Power Unit 6 at Kozloduy NPP took place in 2024. Radiy is an engineering company working in the design, manufacturing and installation of Field Programmable Gate Array (FPGA)-based digital instrumentation and control systems for nuclear power plants and research reactors. Radics also delivers instrumentation and control systems to improve plant safety and reduce maintenance cost. Radiy/Radics LLC designed, manufactured, delivered, and commissioned the Reactor Trip System and Reactor Power Discharge and Limitation Equipment. These systems were designed and developed based on the advanced digital RadICS Platform, in which the components adhere to the latest IEC standards for safety critical services in the highest classified nuclear systems. The RadICS Platform includes a Logic Module, basic input/output modules, and specialty modules all housed in a seismically qualified chassis. Certified as SIL 3 capable in a single channel by exida in 2014 and approved by the US Nuclear Regulatory Commission in 2019, the RadICS Platform has proven reliability in safety-related applications. This latest project followed on from an earlier initiative
from Radics to replace outdated equipment at Kozloduy dating back to 2007. The earlier project saw the installation of a new Engineered Safety Features Actuation System (ESFAS) units at Units 5 and 6. This upgrade improved plant operations, enhanced safety, reduced operating costs, and mitigated risks of technological obsolescence. Designed with advanced FPGA technology, the ESFAS systems installed in 2008 have operated flawlessly for over 15 years, underscoring the benefits of plant modernisation.
More advanced modernisation The newly installed RadICS-based equipment replaced older Russian-made systems and deliver substantial improvements, significantly enhancing operational safety and reliability. Value-added benefits include:
Reliability enhancements: ● Simplified system design: A reduction in total system
modules and cables thanks to FPGA technology and optical communication channels.
● Increased cybersecurity: Redesigned digital networks enhance cyber resilience, ensuring no interference with Class 2(A) equipment.
● Advanced self-diagnostics: Covers over 95% of potential faults, ensuring rapid troubleshooting and fault indication.
● Improved data archiving: Duplicated servers archive process and diagnostic information with a resolution of 5 milliseconds, enabling detailed emergency analysis.
Operational enhancements: ● Improved control algorithms: Enhanced algorithms for
power regulation provide more accurate adaptation to reactor kinetics equations.
● Accurate power calculations: Refined calculations of plant thermal power and operational limits during various equipment shutdowns.
● Optimised repair procedures: Refuelling machines and polar cranes now adapt to seismic sensor data for improved repair processes.
● False protection reduction: The principle of ‘2oo3’ – two out of three majority voting are required for the system to operate – data processing at all levels, including output generators, minimises any false protection activations.
● Fault propagation prevention: Extensive use of galvanic signal separation improves safety during transmission, processing, and output command generation.
Personnel and maintenance benefits: ● Hot-swap functionality: Allows replacement of system modules without de-energizing.
● Error prevention in module installation: A mechanical coding system prevents incorrect module placement.
● Enhanced protection settings: Special engineering stations with secure communication channels facilitate prompt adjustments.
● Streamlined diagnostics: Advanced diagnostic systems display module statuses and pinpoint failed components.
● Algorithm verification automation: An automated system reduces verification time and documentation requirements.
● Process simulation and monitoring: Operational displays provide real-time plant parameters, including built- in simulation capabilities for power regulation and limitation.
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