Nuclear Division | Scientech

Nuclear Plant Products and Services

Plant Process Computer Systems

The first Plant Process Computer (PPC) design was driven

by the need to monitor, record and present a few key
operating parameters to plant personnel.
Over many years PPC has evolved to become a critical monitoring and display
component that aids the operators in maintaining safe, reliable and efficient
operation of the plant. Conceptually simple, as illustrated in Exhibit 1, system
complexity has grown exponentially since its inception in the late 1970s. The
challenge facing system providers is to deconstruct that complexity, eliminate
inter-component dependencies and create fully transportable modular solutions
that are supported by current and future technology advancements.

Exhibit 1
 Plant Process Computer Systems

all PPCs are an I/O system collecting from a few

hundred to more than ten thousand analog and
digital points, a redundant communication network
and server environment including cyber security
components, a complex set of large format
displays, work stations and associated peripheral
devices and the nuclear software applications
The key to achieving the modernization goals executing on the platform. Depending on the
lies in a system resource management platform original plant design the components may be
that resides over the operating system and centrally located or widely distributed throughout
manages the services that it provides to the the site. There are also a host of supporting
nuclear applications and the supporting devices systems such as the Simulator, Annunciator,
in the generating environment. Modularization Radiation Monitoring System, Meteorological
of all software functions and standardization of Tower, Emergency Offsite Facility and Technical
communication among all system components Support Center that also must mesh seamlessly
enables the system’s use of completely standard, to enable all members of the engineering,
off the shelf devices. All of these elements maintenance and operations teams full access
combined form a system structure that to the information they need to maintain plant
supports the use of current technology operation.
and maintains PPC performance to plant
decommissioning. The platform is also The Scientech plant information system platform
the basis of an obsolescence elimination is based on a set of products which are used
strategy that dramatically reduces ongoing extensively in nuclear and fossil power generation
maintenance and support costs. worldwide. At its core, the R*TIME Server and
R*TIME Viewer software have been designed from
The single incontrovertible truth about PPCs is the ground up to support the needs of the power
that no two are the same; even sister plants on generation client base. Both products have a 20+
the same site built at the same time. Exhibit 1 is year history of successful application in nuclear
a good representation of a typical system with and fossil generation.
the detail omitted. The four common elements in

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 The single incontrovertible truth about PPCs is
that no two are the same; even sister plants on
the same site built at the same time.

Scientech emphasizes maintaining technologically Flexible and Powerful System

current products and counts a number of industry Platform
firsts among its accomplishments, including:
The Scientech R*TIME Server software has
• All system software developed in industry unique features such as the ability to
C/C++/C#. In today’s software environment simultaneously support up to 16 databases active
“C” offers clients a platform more resistant in a single server environment. Each of the 16
to technological obsolescence that is much databases is capable of supporting over 60,000
more easily maintained by the evolving analog and 60,000 digital data points. The R*TIME
workforce. Server database management tools facilitates
on-line modification of virtually every database field
• First to deploy a plant computer platform to include the ability to add and delete database
operating completely in a UNIX environment points while the system is in operation.
(Palo Verde).
The multiple database environments provide
• First to deploy a plant computer platform users the benefits of being able to accomplish
operating completely in a Windows functional segmentation of system activities where
environment (TMI). appropriate, as well as, permitting nearly unlimited
• First to deploy systems in a Microsoft system expansion. The multiple database
Windows 2008 environment (Hope Creek capability has also proven very valuable for parallel
and Millstone) and embrace Windows system validation and testing.
domain control as one facet of an The Server and database environment support 12
environment that addresses evolving database-configurable alarm limits for each point
cyber security requirements and patch in the system. Alarm limits may be constant or may
management needs in the domain be variable based on the value of other points in
environment. the system. Alarm limits are plant mode dependent
• First to deploy RTP 2300 and RTP 3000 with support for up to 8 plant modes.
based systems. Scientech maintains a close
working relationship with RTP and is always
an early adapter of new technology from
RTP.

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 Plant Process Computer Systems

In addition to the 12 database configurable limits, OPC and Modbus interfaces and has gateway
the system provides support for Operator based interfaces for DNP-3 to name but a few.
limits. Operator based limits may be applied to
Scientech has field proven standard interfaces
any point in the system using on line tools without
available for 3rd party commercial historian
altering the pre-configured database limits. This
products such the OSI PI and the InStep eDNA
feature gives operators control of cautionary alarms
products.
or alarms desired for certain plant evolutions
without altering System Alarms. Data accessibility is a key issue in today’s
computing environment. While many systems have
Integrated with the server is an archive environment
the ability to collect and store information, making
designed to provide reliable data storage and
that information easily available to the end user in a
reconstructions. The archive system is able to
convenient and useable format can be a challenge.
record analog data as fast as 4 milliseconds and
In addition to making data ODBC-accessible, the
does not use exception based processing or
Scientech R*TIME environment provides an easy
compression which assures reliable, accurate data
to use Excel interface that brings real-time and
reconstruction.
historical data to the users’ desktop with ease.
In a redundant server environment, the archive
In a typical Scientech R*TIME deployment, the
system provides redundancy features that assure
Public Server System extends data access to the
accurate recording and reconstruction even in
corporate desktop. Data provided to the corporate
failover conditions. The R*TIME archives fully
user is time synchronized with the plant computer
support local disk archive, NAS based archive and
environment assuring what the corporate user is
SAN based archive systems.
viewing is consistent with what the operators on
Virtually all data in the on-line system is accessible the protected network see.
by off-line products such as Microsoft Access,
Word, and Excel through an ODBC compliant
interface to R*TIME. In addition to having support
for in excess of 75 proprietary or legacy interfaces,
the Scientech R*TIME product natively supports

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Extensive Diagnostic Capability condition. The monitoring capability extends into
network switches where internal switch health
The base Scientech R*TIME offering fully integrates
and individual port conditions can be monitored.
the RTP I/O system to include RTP diagnostic
Monitoring extends further into the display
capability. The basic R*TIME system health
workstations used to drive the control room
and monitoring processes collect chassis, card
display environment. In some instances monitoring
and point health information which is used to
capability has been extended to printers located in
determine overall system health as well as point
the environment.
status. Information such as power supply status,
redundant communication status, processor In addition to its benefits for monitoring system
health information card status and where available, health and possibly preventing system or
point health are all reported though the DAS component failures, monitoring now incorporates
communication process and rolled up to present part of the cyber security threat mitigation strategy.
an overall picture of DAS and System health. Not only can active network ports be monitored
for health and activity, ports intended to be inactive
Scientech has also taken the traditional concept
can be monitored and alarmed if they become
of system health information and extended it into
active, allowing administrative staff to quickly take
the “peripheral” arteries of the process system. As
appropriate action. Note that the multiple database
the traditional Plant Computer environment has
capability offered by the R*TIME server allows the
evolved, designs have taken greater advantage of
extensive system health and monitoring database
potential redundancy options offered by modern
to be separated from the data typically available
computing and network environments. While the
to plant operators. This capability allows the IT
redundancy options can result in increased system
staff to have full access to data and health alarms
availability they can also result in a false sense of
without distracting or impacting operators with
security. If the health of redundant components is
computer health information.
not actively monitored, they cannot be trusted to
be available when needed.

In a Scientech design nearly every component

is monitored for health and availability. The
capability includes monitoring redundant power
supplies in server computers and internal server
parameters such as temperatures and fan

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 Plant Process Computer Systems

caching for data points that are critical in providing

almost instantaneous trend fills.

Screen navigation can be accomplished through

virtually any pointing device, touch screen and
standard keyboard. Screen navigation can also
The Scientech R*TIME Data Viewer be computer controlled with computer directed
Scientech has invested heavily in its data viewing screens based on plant conditions.
technology. R*TIME Data Viewer is designed to
seamlessly integrate data from the R*TIME server Software Development Process
environment. The Data Viewer design stems from Scientech uses a proven software design control
the needs of the nuclear industry and is highly methodology for software development that meets
tuned to the nuclear operations environment. applicable ASME NQA and IEEE requirements.
The product is a full-featured graphical user These controls include a design process with
environment with a drag and drop display building procedures for the preliminary and final design
environment. Scientech maintains complete phases as well as the implementation and testing
control of the product and does not rely on third phase. Major review processes are performed
party software or technology which maintains our in-house on the specifications, detailed designs,
unparalleled ability to continue to tailor the product acceptance test procedures, manuals and
to the needs of the Scientech client base. documentation as required by the project Quality
Assurance Plan. Software development activities
Viewer has unique features such as the ability to
are performed using Scientech Standard Operating
integrate data from up to 64 data sources (R*TIME
Procedure SOP 20.1, Software Development and
databases) into a single viewer environment and
Control.
indeed to a single R*TIME screen. The ability
to handle multiple data sources has significant Scientech procedures require, as part of standard
implications when considering fleet monitoring system development methodology, a thorough
options. software configuration management system.
This system provides comprehensive controls for
On the performance side, the viewer supports
software development during all phases of the
archive playback, high speed screen updates as
project. Scientech uses a Serena product, PVCS
fast as 250 milliseconds and supports local archive

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 The Data Viewer design stems from the needs
of the nuclear industry and is highly tuned to
the nuclear operations environment.

Version Manager, for maintaining configuration change to the software is requested, an entry into
control on all its software products. The Scientech TestTrack Pro is initiated, a number is assigned
engineering standards and procedures govern the and logged and the problem/change request is
practices and procedures used in the preparation assigned to a responsible individual. After the
and document control of all Scientech designs, correction/change is completed, the resolution is
drawings, specifications and procedures. These recorded in TestTrack Pro and its status is updated
standards are used to ensure that all products are in the log. The process is monitored to assure
designed and operate properly and are configured that problems and requested changes are being
in accordance with current revisions of the addressed in a timely manner.
documentation.
Formal system testing is performed using
Scientech maintains a thorough, fully integrated test procedures that have been reviewed and
Quality Assurance (QA) program as part of its approved. This testing follows successful
normal software and hardware design process. completion of a dry run test of the integrated
This program is referred to as an “in process” system using those procedures. The objective
QA program. The in process QA activities are of the system testing is to demonstrate and
those normally performed by the Scientech QA document the compliance of the integrated system
organizations as required and controlled by the with the plant requirements.
design control procedures.
The project team and cognizant engineering
Each Plant Process Computer replacement personnel prepare the procedures. The documents
project generates a Project Quality Assurance address testing requirements, philosophy,
Plan (PQAP). The PQAP defines the project environment, specification, procedures and
specific implementation of the quality requirements detailed test descriptions. The collection of test
identified in the Scientech QA Manual including, cases is selected to provide a fully-integrated
where required, any Independent Validation and functional test of the system. The appropriate
Verification (IV&V) for certain PPC applications. functional organizations, in conjunction with
the Project Manager, are responsible for the
Scientech uses Seapine’s TestTrack Pro to
preparation, independent review, approval, release,
document reported problems and the corrections
control and revision of these test documents.
for the problems. When a problem is reported or a

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 Plant Process Computer Systems

• Engineering Change Package Lead Times –

Each utility has their own requirements for
lead times for review and acceptance of the
Engineering Change Package for a Plant
Project Time Line/Execution Process Computer replacement project.
While there are a great many variables in the Scientech has encountered lead times for the
completion of a Plant Process Computer approved ECP from 6 to 15 months prior to the
replacement project, our typical completion time PPC installation.
is approximately 18 to 24 months from contract
award. A few major variables that come into play The normal development process begins with
are generally: detailed system design. On the hardware side
of the design, a hardware design document is
• Plant Outage Schedules – Even if an produced. The goal of the document is to translate
installation is not intended to be outage based, specification requirements into a hardware list and
the availability of plant personnel to support design that communicates to the client exactly
outage requirements impacts document review what they should expect to receive and how it will
schedules, and in some cases, impacts staff be configured. The document enables the client to
availability for activities such as factory testing. determine if the hardware design has been properly
interpreted and will be implemented in a manner
• Phased Installation Schedules – Phased
consistent with the plant needs. The document
projects have the advantage of breaking
also has a primary purpose of conveying, to the
execution and installation into smaller and
architect engineer on the project, the details
presumably more manageable tasks. Phased
needed to complete the plant design package.
projects also tend to take longer and cost more
to execute to completion. On the software side of the design, a Project
Standards Document is developed early in
• Plant Urgency – On occasion, plants delay
the project. This document defines systemic
replacement to a point where existing systems
standards to be used in the configuration of the
have become critically fragile and have begun
R*TIME server, development of system displays,
to negatively impact generation. In these cases,
development of plant-specific software as well as
efforts are made to accelerate normal process
any special user interface consideration.
schedules.

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 The normal development process begins with
detailed system design.

Some system aspects defined in the Project Obsolescence Management and

Standards Document include: Mitigation
• Definition of alarm colors and behavior
The Scientech EverGreen process offers the
• Definition of quality propagation rules promise of eliminating the major modification
• Definition of display header information replacement paradigm of the plant information
system with the achievable goal of extending the
• General rules for display navigation
system’s viability to end-of-plant-life.
• Use of color, font, line size, etc. on displays
Process computer hardware and software have
• Any special rules related to shape behavior
dramatically different economic and operational
such as pumps, valves and motors
life cycles than the I/O systems to which they
The document communicates to the development are interfaced. I/O systems have exhibited much
team the core set of rules to be followed in longer term stability and viability than computer
application development. systems. However, their end-of-life migration paths
have also proved less predictable and potentially
Coincident with establishing the core rules more disruptive than the end-of-life migration path
the Software Requirements Specifications for computer hardware.
are developed. These may be developed by
Scientech and reviewed by the Client or provided Scientech has developed and fielded the
to Scientech by the Client. Once agreed upon Refresh Strategy as one element of the
requirements are established, those requirements Evergreen process. Refresh recognizes aging and
are translated into more detailed software design obsolescence issues in system components and
documents. Scientech then develops software and software and provides specific mitigation activities
test procedures from the design information. that prevent system age from compromising safe,
reliable and efficient operation of the plant to end-
of-life and through decommissioning. The Refresh
strategy also has the advantage of significantly
reducing cost for ongoing system maintenance
and support.

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 Plant Process Computer Systems

plant to define and configure firewalls that fulfill all

cyber security requirements.
Cyber Security Aware
While most in the industry understand that The Overall Scientech Advantage
complying with the evolving cyber security Scientech is the leader in the Plant Information
guidance is a difficult to manage situation, Technology business both in nuclear and non-
Scientech continues to develop its products nuclear segments. As mentioned previously,
to be compliant with the continually advancing Scientech has a number of technology firsts.
requirements. As mentioned earlier, in a Windows Scientech is also leading the way with advanced
environment domain controllers assist in enforcing service and maintenance options. One key to
security policies. The use of protocols that our ability to maintain a leadership position is
require a minimum of open ports in firewalls helps a workforce that is balanced with a blend of
maintain firewall effectiveness. Scientech provides seasoned, experienced nuclear industry veterans
technology to help secure interfaces from higher and augmented by a growing influx of young,
security layers to the PPC and from the PPC to fresh talent. The Scientech Plant Process Systems
lower security layers including managing the use workforce has nearly doubled in the past 10
of vulnerable technologies such as OPC. We offer years. Technology that is current and familiar to
multiple solutions for integrating control system today’s college engineering graduate has enabled
data into the PPC in a secure manner. Scientech significant growth from the bottom up and has
continuously monitors industry guidance and offers served to continue to keep the technology we
new communications options that address the provide fresh and forward looking. Previous
desire for unidirectional data flow as required. experience in addressing fleet initiatives has
provided Scientech with unique experience and
On the hardware side of the technology, the use of
perspectives that result in significant economies
managed devices to the maximum extent possible,
of scale, not just in product but in process, which
allows increased physical security on the network.
yield true long-term savings to the fleet.
When used in conjunction with the Scientech
infrastructure diagnostic tools, capabilities for
detection of physical intrusion onto the protected
network are provided. Scientech has developed
interfaces and communication methods to support
all major data diode providers and works with the

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PF-040-5-15-ST-55B-PPS

Delivering Solutions to the Worldwide Power Industry

Scientech, a business unit of Curtiss-Wright, is a global engineering, manufacturing and service company.
Scientech provides plant process computer, digital control, and annunciator systems; thermal performance
software; regulatory information databases and services; nozzle dams and installation services; reactor and
steam generator specialized tooling; under-vessel BWR services and equipment; inventory database services
(RAPID, OIRD) and supply chain analytics; probabilistic risk assessment (PRA) services; repair, refurbish
and reverse engineered I&C services; power supplies; security and access authorization software; mobile
technology applications; and equipment reliability solutions. We are committed to the safe operation and
improved performance and reliability of power plants worldwide.

Nuclear Division | Scientech 1360 Whitewater Drive, Idaho Falls, ID 83402 | [email protected] | http://scientech.cwfc.com | (208) 497-3333