KNOWLEDGE BOOK

AGENSI NUKLEAR MALAYSIA

Pengurusan Pengetahuan Nuklear: Knowledge Book

Siti Nurbahyah Binti Hamdan

[Email address]

COMPUTERISED INFORMATION TECHNOLOGY LTD.

Basic Radiograph Viewer Guide

FROM ANALOGUE TO DIGITAL
INSTRUMENTATION AND CONTROL SYSTEM:
REACTOR TRIGA PUSPATI (RTP) EXPERIENCES

Versi 1.0 Dec 2021
Nuklear Malaysia

Bangi, 43000 Kajang, Selangor, Malaysia
Phone +603-89112000

www.nuclearmalaysia.gov.my

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DOCUMENT CONTROL

DOCUMENT VERSION

Reference No. :

Version : V1.0

Date : Julai 2021

PREPARED BY:

Name Signature

Nurfarhana Ayuni Joha

Julia Abdul Karim

Muhammad Khairul Ariff Mustafa

Nurhayati Ramli

Tonny Anak Lanyau

Norfarizan Mohd Said
Na’im Syauqi Hamzah

Date : Dec 2021

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TABLE OF CONTENTS 2

DOCUMENT CONTROL 5

LIST OF FIGURES 7

LIST OF TABLES 8

1 Introduction to Reaktor TRIGA PUSPATI (RTP) 9
9
1.1 RTP Analogue Instrumentation and Control (I&C) System 14
1.1.1 Analogue Control Console 15
1.1.2 Console Function Key 16
1.1.3 Reactor Operating Modes 17
1.1.4 Manual Modes 18
1.1.5 Automatic Modes 18
1.1.6 Square Wave Modes 18
1.1.7 Pulse Modes 20
1.1.8 Reactor Control System
1.1.9 Reactor Safety and Protection System 21

1.2 Migration from Analogue to Digital I&C 25

2 Reactor Digital Instrumentation and Control System (ReDICS) 25
25
2.1 RTP Instrumentation & Control (I&C) System 27
2.1.1 Reactor Digital Instrumentation and Control System (ReDICS) Project 27
2.1.2 Advantages of ReDICS Project 28
2.1.3 Output of ReDICS Project
2.1.4 Outcome of ReDICS Project 28
28
2.2 Project Implementation 30
2.2.1 ReDICS Project Management 36
2.2.2 Dismantling of RTP Analogue Console 47
2.2.3 Installation of RTP Digital Console
2.2.4 New RTP Digital Console 48

2.3 Handover of ReDICS 50

3 Technology Transfer Programme (TTP) 50

3.1 Human Resources & System Development Programme 50

3.2 TTP at KAERI 53

3.3 TTP at RTP-K 53

3.4 Seminar on Wide-Range Nuclear Monitoring System (WR-NMS) 54
54
3.5 Technical Visit to Korea Nuclear Facility
3.5.1 HANARO

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3.5.2 SHIN-KORI 57
3.5.3 SMART REACTOR (TESTING PLANT) 58
3.5.4 Reactor Experimental Training Course 58

4 Spin-off ReDICS 60

4.1 RTP simulator 60

4.2 Education & Training (E&T) using Simulator 64

5 Conclusion 68

HISTORY OF DOCUMENT REVIEW 68

REFERENCES 69

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LIST OF FIGURES

Figure 1-1 RTP analogue desk-type control console............................................................................ 10
Figure 1-2 Front view of an analogue control console .......................................................................... 11
Figure 1-3 Right-hand drawer of an analogue control console............................................................. 11
Figure 1-4 Left-hand drawer of an analogue control console ............................................................... 12
Figure 1-5 RTP mechanical strip chart recorder ................................................................................... 13
Figure 1-6 Reactor operating console................................................................................................... 14
Table 1-1 Listing of control instruments and indicators on the control console .................................... 14
Figure 1-7 Multi-range linear channel range switch recorder ............................................................... 16
Figure 1-8 Multi-range linear channel range switch recorder ............................................................... 17
Figure 1-9 Early days of RTP operation................................................................................................ 21
Figure 1-10 RTP Analogue Console ..................................................................................................... 22
Figure 1-11 Development stage of the ReDICS Project ....................................................................... 23
Figure 2-1 ReDICS Project Management Structure ............................................................................. 29
Figure 2-2 Flow chart of the approval process of Category A modification projects ............................ 30
Figure 2-3 Removing old secondary cooling system cabinet ............................................................... 31
Figure 2-4 The old cabinet was transferred to the reactor hall using a crane ...................................... 31
Figure 2-5 Removing old cables and wires........................................................................................... 32
Figure 2-6 Removing old cables and wires ........................................................................................... 32
Figure 2-7 Removing floor panels in control room ................................................................................ 33
Figure 2-8 Dismantling one of the analogue console cabinets ............................................................. 33
Figure 2-9 The research officers and assistant engineers are working together.................................. 34
Figure 2-10 RTP staffs are doing electrical wiring and cabling work .................................................... 34
Figure 2-11 Discussing to find solutions for the problems during the work .......................................... 35
Figure 2-12 Frame of the analogue console after dismantling ............................................................. 35
Figure 2-13 Cable wiring and routing .................................................................................................... 36
Figure 2-14 Consignment arrived from Port Klang ............................................................................... 37
Figure 2-15 Unpacked and inspected components arrived based on the packaging list ..................... 37
Figure 2-16 ReDICS cabinet transferred from the RTP hall to the control room .................................. 38
Figure 2-17 Crane used to transfer the cabinet to the control room ..................................................... 38
Figure 2-18 Received cabinet from the ground staff............................................................................. 39
Figure 2-19 Cabinet installation for Operator Workstation (OWS)........................................................ 39
Figure 2-20 Data Acquisition and Control System (DACS) cabinet...................................................... 40
Figure 2-21 All ReDICS cabinets are placed in the control room ......................................................... 41
Figure 2-22 Checking on the wiring of the terminal block at the RPS cabinet...................................... 41
Figure 2-23 Pull out signal cables from reactor top to the control room ............................................... 42
Figure 2-24 Installation of a large display panel in the control room .................................................... 42
Figure 2-25 Pull out fission chamber from the reactor core .................................................................. 43
Figure 2-26 Terminal check for neutron measurement system ............................................................ 43
Figure 2-27 Installation of control rods ............................................................................................. 44
Figure 2-28 Checking of control rod drive mechanism ......................................................................... 44
Figure 2-29 Checking and testing of Operator Work Station (OWS) .................................................... 46
Figure 2-30 ReDICS testing performed by Nuklear Malaysia and KAERI ............................................ 47
Figure 2-31 System inspection by the AELB ........................................................................................ 47
Figure 2-32 ReDICS (2014-present) ..................................................................................................... 48
Figure 2-33 The Minister of MOSTI is interested in ReDICS ................................................................ 49
Figure 2-34 The Minister of MOSTI officially inaugurate the operation of ReDICS .............................. 49
Table 3-1 Lists of training...................................................................................................................... 51
Table 3-2 Mentoring activities ............................................................................................................... 51
Figure 3-1 Reactor personnel during TTP at KAERI ............................................................................ 52

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Figure 3-2 TTP at RTP-K ...................................................................................................................... 53
Figure 3-3 Visit to HANARO.................................................................................................................. 55
Figure 3-4 Radioisotope facility in HANARO ........................................................................................ 56
Figure 3-5 Cold neutron guide hall........................................................................................................ 57
Figure 3-6 Visit to the Shin Kori nuclear power plant............................................................................ 57
Figure 3-7 Visit to the SMART reactor testing plant ............................................................................. 58
Figure 3-8 Reactor experiment course at Kyung Hee University.......................................................... 59
Figure 4-1 Before and after transforming old console into RTP Simulator ........................................... 61
Figure 4-2 Back panels of the RTP Simulator....................................................................................... 61
Figure 4-3 Human-machine interface ................................................................................................... 62
Figure 4-4 Operator workstation (OWS) ............................................................................................... 62
Figure 4-5 Reactor Protection System (RPS) ....................................................................................... 63
Figure 4-6 Data Acquisition and Control System (DACS) .................................................................... 63
Figure 4-7 RTP Simulator Laboratory ................................................................................................... 64
Figure 4-8 Students from Sudan University of Science & Technology (SUST) .................................... 65
Figure 4-9 Nuclear Science postgraduate students from UKM ............................................................ 66
Figure 4-10 Nuclear Engineering students from UTM .......................................................................... 66
Figure 4-11 Students from Indonesia.................................................................................................... 67

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LIST OF TABLES

Table 1-1 Listing of control instruments and indicators on the control console .................................... 14
Table 3-1 Lists of training...................................................................................................................... 51
Table 3-2 Mentoring activities ............................................................................................................... 51

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1 Introduction to Reaktor TRIGA PUSPATI (RTP)

The establishment of Pusat Penyelidikan Atom Tun Dr. Ismail (PUSPATI) in 1973
was purposedly to install and commission a new research reactor and its associated
laboratories for energy research. The PUSPATI TRIGA Reactor (RTP) reached its
first criticality on 28th June 1982, when it was commissioned as the only research
reactor in Malaysia. It has well demonstrated safe operation and high-performance
maintenance for about 40 years. TRIGA (Training, Research, Isotope production,
General Atomic) is a pool-type light water reactor designed and manufactured by
General Atomics, Inc.

RTP is a 1-Megawatt TRIGA Mark II type with a cylindrical core located at the bottom
of a seven-meter-deep aluminium water tank and surrounded by a high-density
concrete biological shielding. The reactor fuel is uranium and zirconium-hydride (U-
ZrH1.6) with 8.5 wt%, 12 wt% and 20 wt% of standard TRIGA fuel type. The
demineralised light water serves as coolant, moderator and shielding, while graphite
is a neutron reflector.

The RTP has been used for education and training, researches and sample

irradiations. Among the main stakeholders of the reactor were local universities,

research institutes, in-house researchers, industries and others related. The Reactor

Technology Centre (PTR), Technical Support Division, is responsible for ensuring

the safe operation with strictly adapted to the integrated management system in any

activities related to the operational and maintaining the reactor. Several

programmes were carried out in-house, including the periodic maintenance,

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inspection, routine daily start-up and shutdown checklist before and after the reactor
operation.

1.1 RTP Analogue Instrumentation and Control (I&C) System

Before 2014, the RTP operation was controlled using analogue instrumentation and
control (I&C) system manufactured and supplied by General Atomics, Inc. The
reactor protection system (RPS) and reactor control and monitoring system (RCMS)
were hardwired using old-fashioned microprocessors and programmable logic
controllers in a single safety channel. The I&C was connected to the reactor core
and control rod drives detectors, using a special interlock system for safety and
protection. The operational parameters are displayed and monitored by a chart
recorder. However, as the technology moved forward, the analogues systems could
not obtain spare or replacement parts and can be cumbersome to the system
maintenance.

1.1.1 Analogue Control Console

The RTP analogue console cabinet size is about 208 cm long, 102 cm wide, and 102
cm tall. The console layout design has been considering the human engineering
aspects. Numerous control buttons, meters, displays, recorders operated by the
operator-on-duty were layout accordingly for optimum readability and accessibility
from the desk control console (Figure 1-1, Figure 1-2, Figure 1-3 and Figure 1-4).
Due to its low profile, the console was set up for easy observation at the
experimental area and the control instruments. The console cabinets housed the
microprocessors and programmable logic controllers for plant process monitoring
and control purposes. The use of microprocessors is not new in nuclear plant and
have been used since the 1980s. The electronic modules, logic system, and relays

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are contained either in pull-out drawers or on swinging doors at the back of the desk
console cabinet for easy and complete access to the equipment are possible while it
is in operation—this aids in maintenance and adjustment procedures.

Figure 1-1 RTP analogue desk-type control console

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Figure 1-2 Front view of an analogue control console

Figure 1-3 Right-hand drawer of an analogue control console

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Figure 1-4 Left-hand drawer of an analogue control console
A chart recorder display mechanism was used to monitor and understand the
behaviour of the reactor power. The reading from the log and linear power over the
entire range is displayed on the same 25.4 cm (10in) chart paper using a dual-pen
recorder (Figure 1-5). The log power readings allow later determination of range
used for the linear power so that both accurate indication and recording of the
reactor parameters are obtained simultaneously. Care has been used in the console
design to display those variables and annunciators essential to the reactor operation
and safety without confusing the information with non-essential auxiliary information.
The console and instrument system also includes various operating modes; manual
steady-state, automatic steady-state (servo control), pulse and square wave.

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Figure 1-5 RTP mechanical strip chart recorder

The electronic circuit boards plug into a nuclear instrumentation module (NIM) bin
mounted either on a swinging panel in the rear or on desk drawers on the front panel
and can pull out to access the electronic modules mounted behind the panel. All
instrument components are high-quality industrial-grade that meet military
specifications. The material used is from solid-state devices for high reliability and
reduced size. The integrated circuits that have been used extensively were
designed to withstand high temperature and fire-resistant material. The number of
components was derated to improve reliability, and circuit reliability analyses were
performed for all reactor safety system modules. Recommended testing intervals
based on the predicted mean time between failures. Using a plug enhances overall
system reliability in circuit boards, and integrated circuits in several instruments
reduce the necessary inventory or repair components and simplify maintenance.
All modules have undergone quality assurance inspection and test and the standard
quality assurance inspection and spot testing of incoming components used in
constructing these modules. After fabrication of the console, the complete system is
tested with simulated inputs to verify the proper operation of the control console and
ensure no undesirable interactions between the circuits. Test on critical nuclear

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channels in a reactor done and operational at an elevated temperature for an
extended period to allow location and replacement of any temperature-sensitive or
weak components. Failures in the electronic modules during a total operating period
of several hundred thousand hours are shallow. Most of these have been failures
induced by human error by the failure of an external sensor or device.

1.1.2 Console Function Key
Meters, switches, and the recorder used to operate the reactor are mounted on the
console control panels (Figure 1-6). The control and indicating devices located on
RTP analogue console are briefly described in Table 1-1.

Figure 1-6 Reactor operating console
Table 1-1 Listing of control instruments and indicators on the control console
No Function
1. Console power on switch
2. Reactor operate key switch

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3. Transient rod fire button
4. Control rod up/low/contact button and indicator lights
5. Control rod position indicator
6. Mode selector switch (automatic, manual, square wave, pulse hi, pulse lo)
7. Reactor power range switch
8. Dual pen chart recorder
9. Flux control % demand
10. Control rod SCRAM bar
11. Period meter, calibrate-operate and trip test switch
12. Fuel temperature meter, calibrate-operate and trip test switch
13. Safety channel meter, zero-calibrate-operate and trip test switch
14. Trip reset button and annunciator
15. 18 annunciators
16. Water temperature meter and select switch (inlet, bulk, outlet)
17. Fuel temperature meter, operate, calibrate and trip test switch
18. Safety channel meter, operate, calibrate and trip test switch
19. Trip reset button and annunciator

1.1.3 Reactor Operating Modes

The reactor can be operated in four modes: manual, automatic, square-wave, and
pulse. The manual and automatic modes are steady-state power modes. The
manual mode is selected by setting the MODE SELECTOR switch to the MANUAL
position (Figure 1-1). The manual and automatic reactor control modes are used to
operate from source level to 100% power. These two modes are used for manual
reactor start-up, change in power level, and steady-state operation. The square-
wave operation allows the power level to be raised quickly to the desired power
level. The pulse mode generates high-power levels in a short time.

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Figure 1-7 Multi-range linear channel range switch recorder

1.1.4 Manual Modes
The manual mode can control the reactor power level from the source level to the full
rated power (100% power). The minimum source-level rod withdrawal prohibited
(RWP) interlock requirements that are two counts per second must be satisfied when
the control rods are withdrawn. The wide range log channel displays the neutron flux
level below the source level to a greater than 100% flux level. The output of this log
channel is dictated by the red pen of the strip chart recorder located in the centre of
the console. At approximately 10-8 % power, depending on the gamma flux level, the
wide range linear channel can detect the neutron flux, and the blue pen of the
recorder will respond. As the power level increases, the operator advances the multi-
range linear channel range switch recorder (Figure 1-8) to keep the channel
sensitivity compatible with the operating flux level.

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Figure 1-8 Multi-range linear channel range switch recorder

1.1.5 Automatic Modes
The automatic mode is identical to the manual mode except that a feedback control
system controls the regulating rod position to regulate the reactor power level as
detected by the wide range linear channel. The multi-range linear channel can
initiate the automatic operation mode at any desired power level, at least after
operating 10W in a manual mode. The operator determined the regulator setpoint by
adjusting the DEMAND control button located to the right of the strip chart recorder.
The period signal is also connected to the flux regulator to provide a constant,
logarithmic rate of change of power when a significant difference in power level. The
regulating rods are controlled automatically in response to a power level and period
signal through a solid state flux controller. This regulator system uses tachometer
feedback from the regulating rod drive to make a high-performance flux controller
without over-shoot. Reactor power level is compared with the demand level set by
the operator and is used to bring the reactor power to the demand level on a fixed

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pre-set period. The demand level is determined by the range switch position and the
per cent potentiometer. The period control signal input to the flux controller allows
significant power level changes to be made automatically on a continuous period, set
for eight seconds.

1.1.6 Square Wave Modes

The square wave mode is similar to the automatic mode except that a transient
reactivity insertion is used to raise the power rapidly to the desired level. The flux
regulator remains inhibited until the power level rises to the demand level. When the
actual power reaches the demand level, a sensing circuit initiates regulator action,
and the system operates as it does in automatic mode. The only difference is
continued inhibition of the period information input. A 1-kW interlock permits firing the
transient rod if the power level is below 1 kW. Immediately after the transient rod is
fired, the servo system starts to operate and hold the power level pre-set.

1.1.7 Pulse Modes

The pulse mode generates high peak fluxes of power levels within a short time. Two
pulse modes are available for greater low power pulse measurement accuracy.
Pulse Lo has a full-scale sensitivity of about 25% of that of the Pulse Hi scale.

1.1.8 Reactor Control System

The reactor power level is detected by several neutron detectors that cover all power
range of the reactor operation. The reactor power is controlled with neutron-
absorbing materials control rods. The control rod drive mechanism is located on the

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reactor bridge and contains electromechanical devices to control the movement of
the control rods. The control mechanism is provided with a voltage source and a 10-
turn potentiometer to drive a digital voltmeter indicator mounted on the console. Four
control rods are used in operation, i.e., Safety, Shim, Regulating and Transient rods.
These control rods are actuated by push button switches on the control panel. For
each control rod, there is a DOWN and UP switch to operate the drive motor. Rod
position may be read on a digital position indicator for each drive on the reactor
control console. There is also a push-button switch for each rod, which will cause the
rod to drop (reactor SCRAM). By pushing the SCRAM bar, all rods are inserted
simultaneously. Indications of control rod position, power level, and rate of power
changes (i.e. reactor period) are all necessary for the reactor's operation was shown
at the console panel.

Several interlocks prevent the movement of the rods in the UP direction when any of
the following conditions occurs:

i. Two Up switches depressed at the same time
ii. SCRAM or TRIP logic not reset
iii. Source level is below the minimum count
iv. Electromagnet not coupled to the armature
v. Mode switch in one of the pulse positions
vi. Mode switch in AUTOMATIC position (regulating rod only)

However, there is no interlock inhibiting the DOWN direction of the control rods
except in the case of the regulating rod while in the automatic mode. Safety, Shim
and Regulating rods are connected to the drive mechanism using armature and
electromagnet. On the other hand, the Transient rod uses compressed air for upward
movement. During any unsafe situation in operation, instantaneously releasing the
rods inside the reactor core was done by disabling the voltage supply to the
electromagnets and a solenoid valve for air supply.

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1.1.9 Reactor Safety and Protection System

The reactor I&C system is designed to detect abnormalities and protect the reactor
from untoward incidents. The protection system is primarily a measurement system
and logic circuitry that prevents the control rods from being withdrawn or forces the
control rods to be inserted into the core and SCRAM the reactor power. A reactor
protective action interrupts the magnet current and results in the immediate insertion
of all rods under any of the following conditions:

i. Manual SCRAM button is pressed
ii. Loss of main supply to the I&C system console either by switching off the

console key switch, power button or incoming supply not available
iii. Loss of high voltage for the neutron detectors
iv. Loss of power supply to the control rod armature
v. Percent Power exceeds the trip set limit
vi. Fuel temperature exceeds the trip set limit
vii. Opening the I&C console drawer top cover

The annunciators automatically indicate all SCRAM conditions. A manual SCRAM
will also insert the control rods and may be used for a normal fast shutdown of the
reactor. On the reactor panel, a bank of annunciators is available for additional
auxiliary SCRAMs or alarms. The rod drive magnet power is obtained when the
reactor console key is inserted; therefore, even though all instrument circuits are
energised at all times, it will not start when the key is removed from the console. It is
to prevent unauthorised operation of the reactor and yet allow checkout and
calibration of instrument channels by maintenance technicians.

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1.2 Migration from Analogue to Digital I&C

Since 1982, the reactor has been utilising the analogue control system for more than
30 years. The robust control console was designed with the highest military grades
and can performed in various operation modes. Over the years, the performance of
the analogue control console was at its best. However, after reaching 30 years, the
control console started to show ageing. Therefore, the corrective maintenance works
become more frequent compared to the preventive to overcome ageing problems.
Furthermore, due to rapid development in data acquisition and computer
technologies, the issue of spare parts availability and compatibility became
significant. Many spare parts were manufactured in the late 1970s or early 1980s
and were not available on the market, yet they were urgently needed for
replacement.

Figure 1-9 Early days of RTP operation

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Figure 1-10 RTP Analogue Console
This issue has become cumbersome to the reactor operation, and long term
solutions need to be tabled to the management for their consideration. After lengthy
discussions and deliberation, looking at all the possible options, a decision to
modernise and migrate the control console from analogue to digital was agreed in
the meeting. The final decision to migrate to the digital systems will give better
features to overcome and solve many issues, including the increase in system
instability, errors on system’s indicators, non-functional functions, intermittent signals
in the design, increased reactor downtime and increased maintenance time.
The Reactor Technology Division started the Reactor Digital Instrumentation and
Control System (ReDICS) project in 2011 to replace the current analogue system
under the Tenth Malaysia Plan (RMK10) funding resources. The project was in
agreement with the Korea Atomic Energy Research Institute (KAERI) as the leading
vendor of the project through a direct negotiation procurement process. In this
project, KAERI is responsible for technical matters, including the design stage, until
the total commission of the ReDICS. The technology transfer programme has also
been set up to train personnel from the Malaysian Nuclear Agency at the design

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stage until commission and including operation and maintenance of the new digital
control system. Figure 1-11 shows the development stage of the ReDICS project.

Figure 1-11 Development stage of the ReDICS Project

The ReDICS project aims for:
i. replacing the analogue with a fully digital console
ii. ensuring that RTP continues to provide reliable performances and meet
current safety standards
iii. continuation of reactor operation for more than five years
iv. capacity building in nuclear instrumentation and control system
v. technology transfer program

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Since the ReDICS project was the first significant modification and replacement
activity at the RTP, the involvement of the national regulator is compulsory. Though
it is also the first time for the regulator to assess the modification in a research
reactor, they too sought vendor country assistance for this project.

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2 Reactor Digital Instrumentation and Control System
(ReDICS)

2.1 RTP Instrumentation & Control (I&C) System

RTP I&C system has become an ear and eye to the operators during operation. It is
used to monitor reactor parameters and automatically shut down the reactor if the
safety limit exceeds. The functions of the reactor I&C system are as follows;

i. Provides means of monitoring and displaying all reactor parameters such as
neutron flux or reactor power, fuel temperature, water temperature for bulk,
inlet and outlet, control rods position, period or rate of power increase and
recording of power.

ii. Provides a means of protecting the reactor from undue conditions or abnormal
circumstances that could result in an accident. The protection logic will
generate a reactor trip signal that releases all control rods into the core in
case of any abnormality.

iii. Provides means of controlling the reactor power by withdrawing and
positioning the control rods and maintaining and regulating the power to a 'set'
value.

There are four control rods used to control the reactor power;
i. regulating rod
ii. shim rod
iii. safety rod
iv. transient rod

2.1.1 Reactor Digital Instrumentation and Control System (ReDICS) Project

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ReDICS project aims to remove the old analogue console and design, manufacture,
install, and commission a new digital I&C system. The modification project focuses
on the safety and capability aspects; that is, the new design will enhance the
operability of RTP without jeopardising the current safety. In addition, the upgraded
I&C system will have higher reliability, stability and capability to ensure the safe
operation of RTP for its remaining life span.

The current I&C system was carefully studied to identify and investigate the problem
arising during operation, thus proposing the best solution to overcome all the
difficulties in many ways. Many inputs were collected before the project started, and
analyses, including a recommendation from the experts, technical analysis,
operation history, and audit reports, decided to replace the current I&C with a fully
digital system to prevent a worsening ageing problem. The project planning stage
also includes short term and long term mitigations to prevent the same issues
incurred.

The proposal was started in 2008 and sought approval from the Safety Committee of
Safety, Health and Environment of the Malaysian Nuclear Agency. The proposal
also was sent to the Atomic Energy Licensing Board (AELB) for early notification
consideration. All aspects of the safety system were considered, including detailed
system design, technical specification, drawings, procedures, and security features
in the proposal. It also includes human resources capacity and capability building in
the project design. A deal with KAERI was done in 2012 and closed in 2013 through
a direct negotiation process. Although the process was not easy going initially, the
agreement was finally concluded after many discussions and arguments. The work
implementation was started in 2013 until 2014 after being awarded a project contract
to KAERI.

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Several reactor personnel was involved in the ReDICS system development, as
early as in the conceptual design stage until the installation process. In addition,
onsite and offsite training was provided to the reactor personnel at the system's
installation, testing and commissioning phase. KAERI also gave operable training to
the reactor operation and maintenance personnel after the total commissioning
phase. Thus, the success of this project can quantify in many outputs and outcomes
success. Moreover, it also has several advantages compared to the old-fashioned
system.

2.1.2 Advantages of ReDICS Project

Several advantages in this project. Among the advantages;
i. modern and up-to-date nuclear I&C system for easy operable

ii. high fidelity I&C system for safe and reliable reactor operation
iii. spare parts and replacement items available in the market
iv. stable reactor operation guarantee in another decade
v. easy maintenance of the system

tacit knowledge gained during the whole process

2.1.3 The output of ReDICS Project

The ultimate goal of this project can measure through two outputs upon the
completion of this project;

i. One (1) set of Reactor Digital Instrumentation and Control System (ReDICS)
ii. A pool of expertise in reactor instrumentation and control

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2.1.4 The outcome of ReDICS Project

The success of this project in several resultant outcomes;
i. Productive and efficient reactor operation to support the utilisation of the
neutron sources.
ii. Competence and self-reliance personnel in nuclear instrumentation and
control system
iii. Reference model to other countries in modification or modernisation of
reactor control console
iv. Centre of attraction in education and training (E&T) at the national and
international level in a nuclear research reactor

2.2 Project Implementation

2.2.1 ReDICS Project Management

Project management involves planning the project, organising the committee,
recruitment (staffing), directing, monitoring, control, introducing something new
(innovating) and representing. Strong project management allegedly proved the
entire project's success upon completing the project within the time and allocation
provided. Therefore, the project management team is set up at the beginning of the
project for this purpose. The project was led by a project manager responsible for
managing the milestones and reporting the progress to the top management. In
addition, the project management team work closely with the contractor to deliver the
project output as agreed. The project manager was assisted by the technical team,
safety team, quality control team, and project licensing team. Furthermore, the
project manager interacts directly with KAERI any matters related to the technical

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whilst communicating with the Radiation Protection Officer (RPO) or Radiation
Protection Supervisor (RPS) any issues associated pertaining the regulatory
requirements. Figure 2-1 depicts the project management structure within the
project implementation.

Figure 2-1 ReDICS Project Management Structure
To ensure better delivery and avoid any project hiccups, a project management tool
was used to track progress, analyse costs, project documentation and other related.
The ReDICS is a total modification type project that must comply with the regulatory
requirement of the Standards for Modification of Research Reactors (LEM/TEK/53).
It is a modification that implies the;

i. Involve changes in the approved operational limits and conditions,
ii. Affect items importance to safety, or
iii. Entail hazards are different or more likely to occur than those previously

considered.

Figure 2-2 indicates the interaction process between the Malaysian Nuclear Agency
and AELB during different stages of the project implementation. At any phase of the
project implementation, safety documents need to be updated accordingly.

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Figure 2-2 Flow chart of the approval process of Category A modification projects
2.2.2 Dismantling of RTP Analogue Console
The existing control console was dismantled in May 2013 by reactor personnel with
the helped from the contactor before installing the new system. The control console
was removed from the site and relocated to another laboratory. A standard
operating procedure for dismantling and relocating the old control console, installing,
testing and commissioning the new system was developed to satisfy safety
requirements.

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Figure 2-3 Removing old secondary cooling system cabinet

Figure 2-4 The old cabinet was transferred to the reactor hall using a crane

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Figure 2-5 Removing old cables and wires

Figure 2-6 Removing old cables and wires

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Figure 2-7 Removing floor panels in control room

Figure 2-8 Dismantling one of the analogue console cabinets

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Figure 2-9 The research officers and assistant engineers are working together

Figure 2-10 RTP staffs are doing electrical wiring and cabling work

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Figure 2-11 Discussing to find solutions for the problems during the work

Figure 2-12 Frame of the analogue console after dismantling

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Figure 2-13 Cable wiring and routing
2.2.3 Installation of RTP Digital Console
A bulky consignment package shipped from the Republic of Korea arrived at Port
Klang in July 2013. The project team members did the consignment unboxing and
inspecting all components at the reactor hall based on the packaging lists to ensure
no damage or missing parts from the consignment. Then, installation components
were lifted by a crane to the control room and reactor platform for the different
installation processes.

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Figure 2-14 Consignment arrived from Port Klang

Figure 2-15 Unpacked and inspected components arrived based on the packaging list

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Figure 2-16 ReDICS cabinet transferred from the RTP hall to the control room

Figure 2-17 Crane used to transfer the cabinet to the control room

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Figure 2-18 Received cabinet from the ground staff

Figure 2-19 Cabinet installation for Operator Workstation (OWS)

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Figure 2-20 Data Acquisition and Control System (DACS) cabinet

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Figure 2-21 All ReDICS cabinets are placed in the control room

Figure 2-22 Checking on the wiring of the terminal block at the RPS cabinet

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Figure 2-23 Pull out signal cables from reactor top to the control room

Figure 2-24 Installation of a large display panel in the control room

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Figure 2-25 Pull out fission chamber from the reactor core

Figure 2-26 Terminal check for neutron measurement system

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Figure 2-27 Installation of control rods

Figure 2-28 Checking of control rod drive mechanism
The functionality tests of the ReDICS was performed after the installation works.
There are five (5) testing stages after the ReDICS installation;

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i. Site Acceptance Test (SAT)
a) This test verifies that RPS, DACS, OWS, and field instruments perform their
intended functions correctly after installation
b) The SAT includes all the required entities to ensure the basic functional
integrity of the systems and component.

ii. Construction Acceptance Test (CAT)
a) Differential Pressure Type Transmitter
b) RTD
c) Level Transmitter
d) Panel Indicators
e) Area Radiation Monitoring System
f) Control Rod Driving Test
g) Rod Drop Test
h) Seismic Monitoring System

iii. System Performance Test (SPT)
a) Reactor Protection System
b) Data Acquisition and Control System
c) Operator Workstation

iv. Integrated System Test (IST)
a) Under Normal Operating Condition
b) Under Abnormal Operating Condition
c) Loss of Control System
d) Loss of Magnetic Power
e) Loss of Instrument Air
f) Response Time for RPS

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v. Reactor Performance Test (RPT)
a) Rod Worth Measurement
b) Power Ascension
c) Neutron Power Calibration
d) Square-Wave Operation

Figure 2-29 Checking and testing of Operator Work Station (OWS)

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Figure 2-30 ReDICS testing performed by Nuklear Malaysia and KAERI

Figure 2-31 System inspection by the AELB
2.2.4 New RTP Digital Console
ReDICS comprises of Data Acquisition and Control System (DACS), Operator Work
Station (OWS), Reactor Protection System (RPS), Wide Range Neutron Measuring
System (WR-NMS) and Control Rod Drive Mechanism (CRDM). The DACS and

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OWS can record short and long term trends of processes variables essential to
operational safety. Operational reports can be extracted from the ReDICS system
directly for the safety performance reporting to the regulator and in-house safety
assessment. The ReDICS system employed the human-machine interface to
provide accurate and timely plant status information to the reactor operator on duty.
A reactor protection system (RPS) embedded with new digital control will shut down
the operation if any operational limits conditions parameters exceed its set points
and rapidly insert the control rods into the reactor core.

Figure 2-32 ReDICS (2014-present)

2.3 Handover of ReDICS

The ReDICS project has finally completed and commissioned on the 6th March 2014.
The historical moment was celebrated with the handover ceremony of the ReDICS
by Datuk Dr Ewon Ebin, the Minister of Ministry Science, Technology and Innovation
(MOSTI) at RTP.

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Figure 2-33 The Minister of MOSTI is interested in ReDICS

Figure 2-34 The Minister of MOSTI officially inaugurate the operation of ReDICS

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