10.1.The main reasons to modernize instrumentation and control systems at a research reactor are obsolescence of the existing systems (e.g. as a result of the unavailability of spare parts) or an increased failure rate of the systems. These developments can lead to frequent reactor shutdowns and long repair periods, resulting in increasing unavailability of the research reactor. Recommendations on ageing management for research reactors are provided in SSG-10 (Rev. 1) [8].
10.2.An additional reason for modernization is the technological progress in instrumentation and control systems, which can provide greater reliability, improved human–system interfaces, and more extensive and faster data collection and data processing capabilities. Other factors (e.g. new regulatory requirements) may also influence the final decision for modernization of the instrumentation and control systems at a research reactor.
10.3.Before modernizing an instrumentation and control system, information on current limitations and future needs should be collected using experience from the existing system. This includes information from past failures and incidents, which should be documented by event recording systems used at the research reactor. Other weaknesses could be identified from the self-assessment of operational performance, including analysis of even small deviations from normal operation. In addition, possible future problems should be considered, and the potential impact of these problems should be assessed.
10.4.The modification and modernization of instrumentation and control systems should be performed in accordance with the recommendations provided in SSG-24 (Rev. 1) [10] on planning, organizational aspects, safety assessment, implementation and post-implementation aspects, training, and documentation of modifications to the research reactor. Vigorous independent verification and validation should be performed for every change associated with the modification and modernization of instrumentation and control systems at a research reactor.
10.5.A modification to an instrumentation and control system might include a complete replacement of the components of the system. Modifications to existing systems important to safety are required to follow the same procedures for design, construction and commissioning that were applied to the original equipment (see para. 7.101 of SSR-3 [1]). Recommendations on the design of instrumentation and control systems are provided in Section 4 of this Safety Guide.
10.6.Modification of instrumentation and control equipment is expected over the lifetime of a research reactor. In each case, consideration should be given to the function of the equipment being modified and the possible impacts of changing from one technology to another. This may include changing from an analogue system to a digital system or replacing an instrumentation and control system because of a lack of spare parts (i.e. obsolescence).
10.7.When a decision is made to implement a modification to an instrumentation and control system important to safety, the possible effects on the safety of the research reactor are required to be considered and assessed (see para. 7.101 of SSR-3 [1]).
10.8.The operating organization should verify that every modification to an instrumentation and control system has been properly assessed, documented and reported in terms of its potential effects on safety and should ensure that the reactor is not restarted without formal approval after the completion of modifications.
10.9.The design documentation for older instrumentation and control systems might be incomplete or inaccurate. Consequently, major modifications to, or replacement of, such systems might involve some degree of ‘reverse engineering’ to recreate the original design bases and specifications. A full set of documentation reflecting the present configuration of the instrumentation and control systems at the research reactor should be made available.
10.10.A process of verification and updating of the existing documentation in accordance with para. 7.99(e) of SSR-3 [1] should be undertaken prior to commencing any modernization of instrumentation and control systems at a research reactor. Reactor operators and maintenance personnel should collaborate on the updating of this documentation to ensure that all modernization activities are captured in the documentation on configuration management of the systems (see Section 9). The baseline database of instrumentation and control systems described in para. 9.2 should also be updated.
10.11.Verification and updating of existing documentation should start with a high level functional description of the instrumentation and control system architecture, preferably in the form of a diagrammatic representation with an accompanying list of all instrumentation and control systems.
10.12.The operating organization should designate a designer to be responsible for design, integration, documentation and maintenance of modifications to instrumentation and control systems, as well as for training of operating personnel in the use of the new systems. Reference [20] provides details on the responsibilities the designated designer should assume.
10.13.For modifications to an instrumentation and control system, the duties and responsibilities of the operating personnel and personnel with responsibilities in an emergency should be taken into consideration. The effects of the modifications on the interactions of these persons with the systems should be taken into consideration so as to achieve an effective human–machine interface. Section 7 provides recommendations on human factors engineering and the human–machine interface.
10.14.The reliability of new or modified equipment should be taken into consideration, as should the effects of the modification on overall system reliability. Performance of a qualitative analysis (e.g. analysis of failure modes and their effects) may be helpful in determining which parts of the instrumentation and control system might be affected by the modifications and the implications in terms of the ability of the system to perform its safety function.
10.15.In modifying an instrumentation and control system, the effect on the implementation of the concepts of defence in depth and independence should be considered. Safety systems are required to be independent, as far as practicable, of other reactor systems (see Requirement 27 of SSR-3 [1]). In modifying an instrumentation and control system, the development of design guidelines should be considered.
10.16.The effects of complex modifications to an instrumentation and control system will be more difficult to analyse. Careful consideration should be given to the addition of any new functions and to the ability to expand the capabilities of the existing system in the future.
10.17.The qualification of modifications for the expected environmental conditions of the system should be considered. Modifications should be qualified for the relevant service conditions (including the operational environment), and the qualification programme should be based on the safety analysis of the proposed modifications.
10.18.Procedures for change control for instrumentation and control systems at a research reactor should be established, including appropriate procedures and organizational structures for the review and approval of the safety aspects of the modification.
10.19.The following should be considered in the design of upgrades and modifications to instrumentation and control systems:
Any limitations due to the physical characteristics of the research reactor that might restrict the design options for instrumentation and control systems;
The need to maintain consistency between the design of replacement equipment and that of existing instrumentation and control systems (e.g. to reduce the complexity of the overall human–machine interface and the maintenance of the system);
The commercial availability of equipment or technology and the future availability of technical support by manufacturers or third parties for the service life of the equipment.
10.20.The benefits of modifications should be weighed against potential negative consequences for safety, and this assessment should be documented as part of the justification for the changes. Compensatory actions should be implemented to anticipate and prevent negative safety consequences.
10.21.Appropriate training on modified instrumentation and control systems should be provided to relevant personnel to minimize or eliminate the potential for errors.
10.22.The consequences of updating or changing a software tool may be significant and should be subject to an impact assessment (e.g. the upgrade of a compiler could invalidate the results of previous analysis or verification concerning the adequacy of the compiler).
10.23.Modifications to instrumentation and control systems at a research reactor are required to be performed by qualified personnel (see para. 7.99(d) of SSR-3 [1]). The work should be performed under the supervision of the designer and with the authorization of the reactor manager.
10.24.Once complete, and before startup of the research reactor, the installation should be functionally tested in accordance with the recommendations provided in SSG-10 (Rev. 1) [8].
10.25.When an instrumentation and control system is modified or is part of an upgrade, the effort applied in justifying and executing the change should be commensurate with the role and function of the system in ensuring the safety of the research reactor, taking into account both the existing systems and any systems that will remain in operation after the modification or the upgrade. This also applies to software based systems.
10.26.When an instrumentation and control system is replaced, the new instrumentation and control system may, where appropriate, be run in parallel with the old system for a probationary period, until sufficient confidence has been gained in the adequacy of the new system. In this configuration, only the old instrumentation system should be able to control the reactor. During this probationary period, the response of the drivers of the new instrumentation and control system should be registered in an independent acquisition system to assess and compare their responses against the responses of the old system.