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All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

The Strategic Value of Human Factors Engineering in Control Room Modernization

Control room modernization is one of the most challenging and complex upgrade projects that a nuclear power plant can undertake. It can have almost as big an impact on operations as, for example, turbine replacement. The challenges of migrating an analog control system to a distributed control system are already well known and a number of nuclear utilities have embarked upon various levels of effort to upgrade some of the systems in the control room. When planning for control room upgrades, plants have to deal with a multitude of engineering, operational, and regulatory impacts. This will inevitably include several human factors considerations, such as workstation ergonomics, viewing angles, lighting, seating, new interaction modalities, new communication requirements, and new concepts of operation. In helping nuclear power utilities to deal with these challenges, the United States Department of Energy researchers located at Idaho National Laboratory (INL) have developed research-based human factors design and evaluation methods to be used in the development of end-state concepts for modernized control rooms and to manage the various phases of the upgrade life cycle. The methodology includes interactive sessions with operators in INL’s Human System Simulation Laboratory, three-dimensional modeling to visualize control board changes and operator-system interaction, and development of human-system prototypes to evaluate various aspects of proposed modifications. This methodology has been applied at a number of U.S. nuclear power plants where modernization projects are underway, including Exelon’s Braidwood and Byron plants, and Arizona Public Service's Palo Verde plant. It was demonstrated that including this methodology in the plant’s engineering process helps to ensure an integrated and cohesive outcome that is consistent with human factors engineering principles and provide substantial improvement in operator performance.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2016

First-of-A-Kind Control Room Modernization Project Plan

This project plan describes a comprehensive approach to the design of an end-state concept for a modernized control room for Palo Verde. It describes the collaboration arrangement between the DOE LWRS Program Control Room Modernization Project and the APS Palo Verde Nuclear Generating Station. It further describes the role of other collaborators, including the Institute for Energy Technology (IFE) and the Electric Power Research Institute (EPRI). It combines advanced tools, methodologies, and facilities to enable a science-based approach to the validation of applicable engineering and human factors principles for nuclear plant control rooms. It addresses the required project results and documentation to demonstrate compliance with regulatory requirements. It describes the project tasks that will be conducted in the project, and the deliverable reports that will be developed through these tasks. This project plan will be updated as new tasks are added and as project milestones are completed. It will serve as an ongoing description on the project both for project participants and for industry stakeholders.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Human factors and modeling methods in the development of control room modernization concepts - 315

Control room modernization is one of the most challenging and complex upgrade projects that a nuclear power plant can undertake. It can even have a bigger impact on operations than, for example, turbine replacement. The challenges of migrating an analog control system to a distributed control system are already well known and a number of nuclear utilities have embarked upon various levels of effort to upgrade some of the systems in the control room. When planning for control room upgrades, plants have to deal with a multitude of engineering and operational impacts. This will inevitably include several human factors considerations, including physical ergonomics of workstations, viewing angles, lighting, seating, new communication requirements, and new concepts of operation. In helping nuclear power utilities to deal with these challenges, the Idaho National Laboratory (INL) has developed human factors design and evaluation methods to be used in the development of an end-state control room concept and to manage the various phases of the upgrade life cycle. This included interactive sessions with operators in INL's Human System Simulation Laboratory, and three-dimensional modeling to visualize control board changes. To make the various upgrade phases as concrete and as visible as possible, the end-state concept includes a set of visual representations of the control room before and after various upgrade phases to provide the context and a framework within which to consider the various options in the upgrade. This includes the various control systems, human-system interfaces to be replaced, and possible changes to operator workstations. This paper describes how this framework helps to ensure an integrated and cohesive outcome that is consistent with human factors engineering principles and also provide substantial improvement in operator performance. The paper further describes the application of this integrated approach in the strategic modernization program at a nuclear power plant where legacy systems are upgraded to advanced digital technologies through a systematic process that links human factors principles to the systems engineering process. This approach results in an integrated control room architecture beyond what is possible for individual subsystem upgrades alone. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

A HUMAN FACTORS META MODEL FOR U.S. NUCLEAR POWER PLANT CONTROL ROOM MODERNIZATION

Over the last several years, the United States (U.S.) Department of Energy (DOE) has sponsored human factors research and development (R&D) and human factors engineering (HFE) activities through its Light Water Reactor Sustainability (LWRS) program to modernize the main control rooms (MCR) of commercial nuclear power plants (NPP). Idaho National Laboratory (INL), in partnership with numerous commercial nuclear utilities, has conducted some of this R&D to enable the life extension of NPPs (i.e., provide the technical basis for the long-term reliability, productivity, safety, and security of U.S. NPPs). From these activities performed to date, a human factors meta model for U.S. NPP control room modernization can now be formulated. This paper discusses this emergent HFE meta model for NPP control room modernization, with the goal of providing an integrated high level roadmap and guidance on how to perform human factors R&D and HFE for those in the U.S. nuclear industry that are engaging in the process of upgrading their MCRs.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

A human factors meta model for U.S. nuclear power plant control room modernization - 350

Over the last several years, the United States (U.S.) Department of Energy (DOE) has sponsored human factors research and development (R and D) and human factors engineering (HFE) activities through its Light Water Reactor Sustainability (LWRS) program to modernize the main control rooms (MCR) of commercial nuclear power plants (NPP). Idaho National Laboratory (INL), in partnership with numerous commercial nuclear utilities, has conducted some of this R and D to enable the life extension of NPPs (i.e., provide the technical basis for the long-term reliability, productivity, safety, and security of U.S. NPPs). From these activities performed to date, a human factors meta model for U.S. NPP control room modernization can now be formulated. This paper discusses this emergent HFE meta model for NPP control room modernization, with the goal of providing an integrated high-level road map and guidance on how to perform human factors R and D and HFE for those in the U.S. nuclear industry engaged in the process of upgrading their MCRs. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Regulatory Aspects of the Human Factors Engineering Process in Control Room Modernization

This report describes the basic aspects of control room modernization projects in the U.S. nuclear industry and the need for supplementary guidance on the integration of human factors considerations into the licensing and regulatory aspects of digital upgrades. The report pays specific attention to the integration of principles described in NUREG-0711 (Human Factors Engineering Program Review Model) and how supplementary guidance can help to raise general awareness in the industry regarding the complexities of control room modernization projects created by many interdependent regulations, standards and guidelines. The report also describes how human factors engineering principles and methods provided by various resources and international standards can help in navigating through the process of licensing digital upgrades. In particular, the integration of human factors engineering guidance and requirements into the process of licensing digital upgrades can help reduce uncertainty related to development of technical bases for digital upgrades that will avoid the introduction of new failure modes.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Human Factors Engineering Aspects of Modifications in Control Room Modernization

This report describes the basic aspects of control room modernization projects in the U.S. nuclear industry and the need for supplementary guidance on the integration of human factors considerations into the licensing and regulatory aspects of digital upgrades. The report pays specific attention to the integration of principles described in NUREG-0711 (Human Factors Engineering Program Review Model) and how supplementary guidance can help to raise general awareness in the industry regarding the complexities of control room modernization projects created by many interdependent regulations, standards and guidelines. The report also describes how human factors engineering principles and methods provided by various resources and international standards can help in navigating through the process of licensing digital upgrades. In particular, the integration of human factors engineering guidance and requirements into the process of licensing digital upgrades can help reduce uncertainty related to development of technical bases for digital upgrades that will avoid the introduction of new failure modes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Control Room Modernization End-State Design Philosophy

The Control Room Modernization (CRM) research effort is a part of the Light-Water Reactor Sustainability (LWRS) Program, which is a research and development program sponsored by Department of Energy (DOE) and performed in close collaboration with industry research and development programs that provides the technical foundations for licensing and managing the long-term, safe, and economical operation of current nuclear power plants. One of the primary missions of the LWRS program is to help the U.S. nuclear industry adopt new technologies and engineering solutions that facilitate the continued safe operation of the plants and extension of the current operating licenses. This report describes the background and technical basis for an end-state vision design philosophy for and advanced hybrid control room.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2016

A Business Case for Nuclear Plant Control Room Modernization

This paper presents a generic business case for implementation of technology that supports Control Room Modernization (CRM). The analysis presented in two forms; 1) a standalone technology upgrade, and 2) a technology upgrade that is built upon and incremental to a prior business case created for Mobile Work Packages (MWP). The business case contends that advanced communication and networking and analytical technologies will allow NPP to conduct control room operations with improved focus by reducing human factors and redundant manpower, and therefore operate with fewer errors. While some labor savings can be harvested in terms of overtime, the majority of savings are demonstrated as reduced time to take the plant off line and bring back on line in support of outages. The benefits are quantified to a rough order of magnitude that provides directional guidance to NPPs that are interested in developing a similar business case. This business case focuses on modernization of the operator control room and does not consider a complete overhaul and modernization of a plants instrument and control systems. While operators may be considering such an investment at their plants, the sizable capital investment required is not likely supported by a cost/benefit analysis alone. More likely, it is driven by obsolescence and reliability issues, and requires consideration of mechanical condition of plant systems, capital depreciation, financing, relicensing and overall viability of the plant asset over a 20-year horizon in a competitive market. Prior studies [REF] have indicated that such a modernization of plant I&C systems, alone or as part of a larger modernization effort, can yield very significant reductions in O&M costs. However, the depth of research and analysis required to develop a meaningful business case for a plant modernization effort is well beyond the scope of this study. While CRM as considered in this study can be easily integrated as part of grander plant modernization effort, it can also be considered as a stand-alone project, implemented as a supervisorial layer over and above existing systems. CRM is enabled by a suite of technologies, which are described in further detail in the body of this report. They include: • Modernized control room with interactive displays • High-bandwidth wireless networks • Mobile devices • Component identification technology • Mobile wireless video cameras • Smart or task based operator displays • Computer-Based Procedures (CBP)/Automated Mobile Work Packages (MWP) • Intelligent plant configuration • Advanced data analytics An analysis was conducted to determine how these technologies might impact outage operations at an NPP. The analysis concluded that outage management capabilities would be improved with application of these technologies, and result in annual benefits for the plant. These improved capabilities were identified and described in further detail in this report. • Reduction in need redundant manpower (verification, etc) • Improved critical path shutdown and restart duration during outages • Reduction in human factors and errors • Remote watches • Paperless outage coordination • Bulk work optimization

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Ergonomic Safety and Health Activities to Support Commercial Nuclear Power Plant Control Room Modernization in the United States

Affordable, abundant, and reliable electricity generation is essential to fueling a nation’s robust and globally competitive economy. In the United States (U.S.), commercial nuclear power plants (NPPs) account for approximately 19% of reliable and cost-competitive baseload electricity generation. Other technologies that reduce reliance on fossil fuels and provide baseload electricity cost-competitively at a national scale are still under development. Thus, without suitable replacements for nuclear power, the generating capacity of nuclear energy in the U.S. must be continued through the safe and efficient operation of commercial NPPs. The U.S. De-partment of Energy’s (DOE) Light Water Reactor Sustainability (LWRS) research and development (R&D) program provides the technical bases for the long-term, safe, and economical operation of NPPs. One area in the LWRS program is the Plant Modernization pathway, which includes human factors R&D, human factors engineering (HFE), and ergonomics to enable the modernization of the instrumentation and control (I&C) technologies in NPP main control rooms (MCRs). DOE researchers, including ergonomics specialists at Idaho National Laboratory (INL) have collaborated with nu-merous commercial NPP utilities over the last few years on control room modernization. This paper summarizes recent ergonomics safety and health R&D and HFE performed in collaboration with a U.S. commercial utility to modernize their NPP MCRs.

99 GENERAL AND MISCELLANEOUS↗
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 OSTI2017

A business case for nuclear plant control room modernization - 352

This paper presents a generic business case for implementation of technology that supports Control Room Modernization (CRM) in existing nuclear power plants (NPPs). The business case is based on advanced digital instrumentation and control (I and C), human-system interface (HSI), and work process technologies that allow NPP operators to conduct control room operations with improved human factors and efficiency, and therefore operate with fewer operational events. Labor savings can be harvested in terms of reduced overtime and redistribution of work. Significant savings are also demonstrated as reduced time to bring the plant back on line after completion of outages. The benefits are quantified to a rough order of magnitude, providing directional guidance to NPPs that are interested in developing similar business cases. The technologies employed in CRM include large overview displays, task-based operator displays, computer-based procedures, advanced alarm systems, computerized operator support systems, and wireless networks, among others. The CRM business case is founded on the following categories of cost savings: - Integrated Computer-Based Procedures for Operators; - Reduction in Corrective Action Program Work Due to Operator Error; - Reduction in Outage Critical Path Time; - Operation of Local Control Panels; - Reduction in Control Room Support; - Reduction in Plant Events Resulting in Generation Loss; - Paperless Control Room Processes. In addition to cost savings, these technologies also offer improvements to indirect ways that have impact on key performance indicators of the plant. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Light Water Reactor Sustainability Program Development of an Initial Business Case Framework for Fleet-Based Control Room Modernization

This milestone report presents a plan or framework for developing a generic business case for implementation of technology that supports Control Room Modernization (CRM) in existing power plants (NPP). The decision fund CRM activities often depends on demonstrating actual cost reductions that can be credited to budgets and thereby truly reduce operations and maintenance (O&M) or capital costs. The proposed Business Case Methodology (BCM) thus addresses the fact that the lack of a business case is often cited by utilities as a barrier to pursuing large-scale CRM activities. Using past BCM analyses for CRM as a model for this framework, this BCM proposes to base cost savings on advanced digital instrumentation and control (I&C), human-system interface (HSI), and work process technologies that allow NPP operators to conduct control room operations with improved human factors and efficiency, and therefore operate with fewer operational events. The technologies employed in CRM include large overview displays, task-based operator displays, computer- based procedures, advanced alarm systems, computerized operator support systems, and wireless networks, among others, but this initial plan will also focus only on a subset of these technologies. Thus, under this BCM model, labor savings can be harvested in terms of reduced overtime and redistribution of work. In short, the BCM addresses the benefits of the technology as opposed to the investment costs of the utility. The methodology provides the means to determine the maximum investment that will result in a positive return. Significant savings are also demonstrated as reduced time to bring the plant back on line after completion of outages. The benefits are quantified to a rough order of magnitude, providing directional guidance to NPPs that are interested in developing similar business cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

APPLICATION OF EYE TRACKING FOR MEASUREMENT AND EVALUATION IN HUMAN FACTORS STUDIES IN CONTROL ROOM MODERNIZATION

An important element of human factors engineering (HFE) pertains to measurement and evaluation (M&E). The role of HFE-M&E should be integrated throughout the entire control room modernization (CRM) process and be used for human-system performance evaluation and diagnostic purposes with resolving potential human engineering deficiencies (HEDs) and other human machine interface (HMI) design issues. NUREG-0711 describes how HFE in CRM should employ a hierarchical set of measures, particularly during integrated system validation (ISV), including plant performance, personnel task performance, situation awareness, cognitive workload, and anthropometric/ physiological factors. Historically, subjective measures have been primarily used since they are easier to collect and do not require specialized equipment. However, there are pitfalls with relying solely on subjective measures in M&E such that negatively impact reliability, sensitivity, and objectivity. As part of comprehensively capturing a diverse set of measures that strengthen findings and inferences made of the benefits from emerging technologies like advanced displays, this paper discusses the value of using eye tracking as an objective method that can be used in M&E. A brief description of eye tracking technology and relevant eye tracking measures is provided. Additionally, technical considerations and the unique challenges with using eye tracking in full-scaled simulations are addressed. Finally, this paper shares preliminary findings regarding the use of a wearable eye tracking system in a full-scale simulator study. These findings should help guide future full-scale simulator studies using eye tracking as a methodology to evaluate human-system performance.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2018

Application of Eye Tracking for Measurement and Evaluation in Human Factors Studies in Control Room Modernization

An important element of human factors engineering (HFE) pertains to measurement and evaluation (M&E). The role of HFE-M&E should be integrated throughout the entire control room modernization (CRM) process and be used for human-system performance evaluation and diagnostic purposes with resolving potential human engineering deficiencies (HEDs) and other human machine interface (HMI) design issues. NUREG-0711 describes how HFE in CRM should employ a hierarchical set of measures, particularly during integrated system validation (ISV), including plant performance, personnel task performance, situation awareness, cognitive workload, and anthropometric/ physiological factors. Historically, subjective measures have been primarily used since they are easier to collect and do not require specialized equipment. However, there are pitfalls with relying solely on subjective measures in M&E such that negatively impact reliability, sensitivity, and objectivity. Furthermore, as part of comprehensively capturing a diverse set of measures that strengthen findings and inferences made of the benefits from emerging technologies like advanced displays, this paper discusses the value of using eye tracking as an objective method that can be used in M&E. A brief description of eye tracking technology and relevant eye tracking measures is provided. Additionally, technical considerations and the unique challenges with using eye tracking in full-scaled simulations are addressed. Finally, this paper shares preliminary findings regarding the use of a wearable eye tracking system in a full-scale simulator study. These findings should help guide future full-scale simulator studies using eye tracking as a methodology to evaluate human-system performance.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Analog, Digital, or Enhanced Human-System Interfaces? Results of an Operator-in-the-Loop Study on Main Control Room Modernization for a Nuclear Power Plant

The second Operator Study of System Overviews (OSSO-2) was conducted with a three-person reactor operator crew in the Human Systems Simulation Laboratory (HSSL) at Idaho National Laboratory (INL) in August, 2017. The study supported control room modernization at a nuclear power plant and featured a benchmark comparison of three variants of a turbine control system (TCS): the existing analog TCS, a proposed standalone digital TCS with two displays, and the digital TCS with the addition of a third display consisting of a system overview screen. TCS prototypes were developed at INL to allow evaluation of operator performance and preferences during realistic turbine scenarios in the full-scope simulator. The study revealed that completion of turbine startup was several minutes faster with the digital TCS variants than with the conventional analog TCS. Eye tracking scan paths were more widely distributed in the overview vs. standalone TCS condition, suggesting the overview screen was cueing reactor operators to verify values across the boards. There was no significant difference in workload or situation awareness across the three interfaces. Reviewing key plant parameters showed smoother transitions during load following for the digital vs. analog TCS. Despite some performance advantages for the digital TCS variants, operators preferred the existing analog TCS. Open-ended responses suggested this finding may be more an artifact of familiarity than a reflection of dissatisfaction with the new TCS. OSSO-2 provides compelling evidence that the new digital TCS was used successfully by the operators without extensive training of rewriting of the operating procedures, suggesting high usability for the digital TCS design. Further advantages were realized through the addition of the system overview screen to provide crews with at-a-glance indicators of key turbine parameters.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

Nuclear Power Plant Control Room Modernization - Simulation Based Design

As many plants age and equipment modifications are implemented, the industry has the opportunity to address the issue of control room obsolescence through technology application and enhanced engineering techniques using existing systems. This paper addresses the practice of Simulation Based Design (SBD) for control room modernization driven by plant modifications and upgrades.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗