Presentation by: Mike Lawton Fit, Form & Function
ABB Canada Replacement
Instrumentation
from ABB Canada
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Jan 24, 2021
Market Environment
Nuclear Power Plants consume less
than 5% of instrumentation produced
in the world
Traditional instruments available when
plants were built have been replaced by
software-based solutions embedded into
DCS/PLC control systems and Smart Instrumentation
Supplier base has been consolidated as instrument manufacturers
now serve global market
Unprofitable or inactive product lines have been taken off the
market
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Case #1 - F&P Series 3000/4000 Process Controllers
Series 3000 & 4000 process controllers
were supplied by F&P Warminster-USA
circa 1965-1985
Mechanical parts no longer manufactured
Model ED, Manual Loader
Model EL, PID Controller
Model EC, Computer-Manual Station
Model EN, Computer-Auto-Manual
Stations
Controllers were typically used in the
Main Control Room, both for Primary
and Back-up control applications
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Design Challenges
Modern standalone controllers are microprocessor based,
with embedded and application software
Display needed to be configured to meet needs of all
stakeholders, including Plant Design, Human Factors Engineering
and Operations
Direct replacement, controller needed to install into original
3 x 6 inch case and connect to original termination cables
Be qualified to unique NPP specifications for transient immunity,
RFI and seismic
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ABB Retrofit Controller Solution
Direct slide-in replacement for
F&P Series 3000 or 4000 controllers
Existing Series 3000/4000 3”x 6”
enclosure remains installed in panel
and new controller is plugged into
existing termination cables
Front display & main control board is
based on former F&P 53MC5000 MicroDCI,
now MicroMod 53MC5000
Interface boards and re-packaging into Series 3000 or 4000 form factor by
ABB Canada
Programming to mimic original display and meet control requirements by
Utility Automation group within ABB Canada
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Custom Displays
Case #2 - Indicating Alarm Units
Original manufacturer discontinued
product to focus on core business,
not related to NPP’s
Need for an analog meter with
alarming capability has been
replaced in general industry by
PLC/DCS’s, digital indicators,
videographic recorders and
computer-based MMI’s
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Design Challenges
Basic analog solution, no embedded software
Unique dimensions, existing product doesn’t comply with DIN
standards
Signals to meter are a mix of standard signals (4-20 mA, 1-5Vdc)
and non-standard signals (0-1 Vdc, 0-1 mA, 0-30 mA, 200 ohm
RTD…)
Custom designed scales
Unique specifications, relay ratings, compatibility with existing
connector…
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Jan 24, 2021
Solution: ABB 5624 Indicators & Indicating Alarm Units
High quality 1/16th DIN indicator & indicating
alarm unit supplied by ABB Germany
Case produced by local Canadian suppliers
to original dimensions
Interface card designed in Canada to convert
non-standard signals into standard signals
and to support alarm LED’s
Relay card designed in Canada to convert
electronic switch contacts from 1/16th DIN
meter to Form C relay contacts
Painted “Surf Green”
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Case # 3 - Signal Conditioning Modules
These modules were largely replaced by software function codes
embedded into PLC/DCS control systems and Smart
Instrumentation
Including, square root extractors, high, low & median selector
stations, adder/subtractors, multipliers, dividers, inverters, limiters…
Main stream suppliers from 1970’s don’t offer a direct hardware
based replacement
+ - ∫ 12-20mA
÷ x 1/x 4-12mA
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Design Challenges
No microprocessors or embedded software
SMT (surface mount technology)
1:1 replacement
Employ more modern IC circuits (i.e. constant current sources)
and replace older technologies (i.e. Wheatstone bridge circuits)
Replace linear power supplies with more efficient switching power
supplies
Meet unique specifications for NPP, including transient immunity,
RFI immunity and Siesmic
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Solution: Signal Conditioning Modules
Enclosure & terminals are identical to
original modules
New circuit boards do not have embedded
software, are built using modern
Surface Mount (SMT) components
Linear Power supply was replaced with a
highly efficient switching power supply to
prevent heat build-up within enclosure
Constant current sources replaced Wheatstone bridges
EPROM to TTL circuit for non-linear applications, including square
root extractors and temperature transmitters
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Global presence…
and Local expertise !
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