ML072480531

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WCN-9715DP, Rev. 2, Nutherm Dedication Plan for Replacement Msfis System.
ML072480531
Person / Time
Site: Wolf Creek Wolf Creek Nuclear Operating Corporation icon.png
Issue date: 08/29/2007
From: Sterbis T
Nutherm International
To:
Office of Nuclear Reactor Regulation, Wolf Creek
References
734527, ET 07-0039 WCN-9715DP, Rev. 2
Download: ML072480531 (31)
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Text

Enclosure I to ET 07-0039 Nutherm International Dedication Plan WCN-9715DP, Revision 2

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 1 OF 29 NUTHERM DEDICATION PLAN FOR REPLACEMENT MSFIS SYSTEM WOLF CREEK NUCLEAR OPERATING CORPORATION PURCHASE ORDER NO. 734527 NUTHERM DOCUMENT NUMBER WCN-9715DP, REV. 2 Prepared By:. Date:

Project Engineering Manager Reviewed and Approved By: Date: f /--ýo 216 --7 Wayne feaver EQ Manager 501 South 11 thStreet Af*utI1erm Mt. Vernon IL 62864 PHONE: 618-244-6000 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 2 OF 29 REVISIONS The revision number is indicated at the top of each page, for all revisions. To delineate the exact location of a given revision, a vertical line is used on the right margin. However, for a complete report rewrite, no vertical lines are used.

REVISION LOG REVISION DATE PAGE SECTION REFERENCE I 5/31/07 5-24 Dedication Description Complete Rewrite 2 All All Renumbered pages 4 Applicable Standards Revised WC specification and Documents Revision 5 Device Description Clarified safety function 6-7 General Clarified general dedication process 7 MSFIS Replacement Revised description System 9-21 Critical Characteristics Revised Matrix Matrix 22-23 Physical Characteristics Clarified process description 24-25 Performance Clarified performance testing purpose 25-26 Dependability Clarified dedication activities 501 South 11tt Street PHONE: 618-244-6000 f*qaLdl Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 3 OF 29 TABLE OF CONTENTS DESCRIPTION PAGE PURPOSE ............................................................................................................ 4 APPLICABLE STANDARDS ANT) DOCUMENTS .......................................................... 4 DEVICE DESCRIPTION.......................................................................................... 5 DEDICATION DESCRIPTION .................................................................................. 6 GENERAL................................................................................................................ 6 MSFIS REPLACEMENT SYSTEM ................................................................................... 7 CRITICAL CHARACTERISTIC MATRIX.................................................................... 9 PHYSICAL CHARACTERISTICS ............................................................................ 22 PERFORMANCE................................................................................................ 24 DEPENDABILITY............................................................................................... 25 VERIFICATION AND VALIDATION ....................................................................... 26 501 South 11 mStreet PHONE: 618-244-6000 I~2ENa7NLgi Nl Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 4 OF 29 PURPOSE The purpose of this dedication plan is to present and define the critical characteristics and the applicable processes and standards which will be used to dedicate the commercial grade items described in the "Device Descriptions" section of this document.

This dedication plan addresses critical characteristics primarily. Additional testing and verification, beyond that required for dedication of the units described in the "Device Descriptions" section of this document, will be performed (as applicable) to ensure items purchased through Nutherm International are the items described in the customers specification sheets and/or Purchase Order.

All qualification work is accomplished in accordance with customer purchase order and specification requirements, Nuclear Regulatory Commission Guidelines, and applicable Institute of Electrical and Electronic Engineers Standards.

APPLICABLE STANDARDS AND DOCUMENTS

  • IEEE 344-1975 -'Recommended Practices for Seismic Qualification of Class IE Equipment for Nuclear Power Generating Stations."
  • IEEE 323-1974 - "Standard for Qualifying Class 1E Equipment for Nuclear Power Generating Stations"
  • 10CFR50, Appendix B. -"Quality Assurance Criteria for Nuclear Power Plants and Fuel Reprocessing Plants"
  • Nutherm International, Inc. Quality Assurance Manual No.: QA-N-10179-5.

0 EPRI NP-5652-"Guideline for the Utilization of Commercial Grade Items in Nuclear Safety Related Applications" 0 EPRI TR-102260-"Supplemental Guidance for the Application of EPRI NP-5652 on the Utilization of Commercial Grade Items" 0 EPRI TR-1 02323-R2-1997 - "Guidelines for Electromagnetic Interference Testing in Power Plants" 0 Regulatory Guide 1.1 80-Rl -"Guidelines for Evaluating Electromagnetic and Radio-Frequency Interference in Safety-Related Instrumentation and Control Systems" 0 IEEE 649-1991 - "Standard for Qualifying Class 1E Motor Control Centers for Nuclear Power Generating Stations"

  • Wolf Creek Generating Station Specification J-105A(Q) 501 South 11th Street PHONE: 618-244-6000 NTIONAL, INC. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 5 OF 29

  • EPRI TR-106439 - "Guideline on Evaluation and Acceptance of Commercial Grade Digital Equipment of Nuclear Safety Applications" DEVICE DESCRIPTION The Main Steam and Feedwater Isolation System (MSFIS) has two distinct functions:

" Steam Line Isolation System (SLIS) - Main Steam Line Isolation minimizes the uncontrolled cool down of the Reactor Coolant System (RCS) that would result from a main steam line rupture. Input signals pass from the detectors through the Solid State Protection System (SSPS) to the MSFIS cabinet where the output signal is generated.

" Feedwater Isolation System (FWIS) - Feedwater isolation minimizes the potential for excessive post-trip cool down of the RCS due to overfilling the steam generators. It also prevents moisture carryover caused by high steam generator levels, and isolates normal Feedwater in the event of a high Energy Line Break inside containment.

MSFIS will include a safety-related logic-controller-based system to perform the control functions of the Main Steam Isolation Valves (MSIVs) and Main Feedwater Isolation Valves (MFIVs) with system-medium actuators. The MSFIS System has two redundant subsystems located in separate cabinets:

MSFIS Channel 1 (1) located in MSFIS Cabinet SA075A (Train A)

MSFIS Channel IV (4) located in MSFIS Cabinet SA075B (Train B)

Each MSFIS cabinet is capable of supplying the control logic outputs required for operating each of the 4 Main Steam Isolation Valves and 4 Main Feedwater Isolation Valves.

Dedication activities will be performed by Nutherm International Inc. on the control system ALS Racks and Assembly Panels for Channels I and IV.

The safety function of the replacement MSFIS controls is to close the MSIV and MFIV when requested by input conditions.

501 South 11 th Street PHONE: 618-244-6000 INTERNATIONAL, INC. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 6 OF 29 DEDICATION DESCRIPTION GENERAL EPRI TR106439 states in Section 1.2:

"The guidance in this document is intended for use by utilities or by other organizations who perform dedication of commercial grade equipment which ultimately is supplied to utilities.

The approach taken in developing this guidance is based on the conclusions reached by the working group that: (1) the existing process for commercial grade dedication can, with appropriate supplemental guidance, be applied to digital equipment, and (2) supplemental guidance provided for digital-specific issues should be consistent with the existing framework established for design and licensing of digital upgrades.

Accordingly, this document supplements and is consistant with existing industry guidance contained in:

EPRI NP-5652, "Guideline for the Utilization of Commercial Grade Items in Nuclear Safety Related Applications."

EPRI TR-102348, "Guideline on Licensing Digital Upgrades," and IEEE 7-4.3.2-1993, "Standard Criteria for Digital Computers in Safety Systems of Nuclear Power Generating Stations.""

Following the recommended practice in EPRI TR106439, Nutherm will base dedication activities on EPRI Report 5652 with "appropriate supplemental guidance" applied to digital-specific issues. As part of that supplemental guidance, Table 4.1, "Critical Characteristics Matrix for Digital Equipment," and Table 6-4, "ESFAS Programmable Logic Controller Characteristics) in EPRI TR-106439 were used as a basis for the development of the dedication activities.

The dedication process, per EPRI Report 5652, assumes that "the design requirements of the item have been satisfactorily translated into specification requirements as reflected in the procurement document." The guideline goes on to describe three fundamental issues which, once addressed, provide a foundation for the acceptance process of a particular item. The three fundamental issues as described in EPRI Report 5652 are as follows:

" Determine the safety function of the item

" Confirm the item is commercial grade

  • Identify critical characteristics.

501 South .11th Street PHONE: 618-244-6000 INTERNATIONAL,/INO. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 7 OF 29 These three fundamental issues are addressed during the technical review process and a Component Dedication Planner (CDP) is generated for each item to be dedicated. In the case of more complex systems such as the MSFIS system a Critical Characteristic Matrix is used to quantify Critical Characteristics and the Verification methods used. The CDP or Critical Characteristic Matrix documents the results of the engineering evaluation performed to identify the design and performance attributes necessary to perform the item's safety function. The Critical Characteristic Matrix for the replacement MSFIS system has been incorporated into this Dedication Plan.

EPRI NP-5652 is used as a guideline for the dedication process of commercial grade items. As stated in section 1.3.4, "the methods in the guideline are in conformance with existing regulatory requirements. The methods for accepting commercial grade items are consistent with the provisions of Criterion VII of Appendix B to IOCFR50 which states:"

"Measures shall. be established to assure that purchased material, equipment, and services, whether purchased directly or through contractors and subcontractors, conform to the procurement documents.

These measures shall include provisions, as appropriate, for source evaluation and selection, objective evidence of quality furnished by the contractor or subcontractor, inspection at the contractor or subcontractor, inspection at the contractor or subcontractor source, and examination of products upon delivery."

Nutherm International has incorporated the guideline into its QA program and in-place procedures for the dedication of commercial grade items. See Figure 1 for a block diagram of the generic dedication process. The methods referred to (Method 1 thru 4) are described in detail in EPRI NP-5652. Nutherm International employs a combination of method I and other acceptance methods. In the case of the MSFIS system, all four acceptance methods will be used. Figure 2 is a schematic logic diagram for employing method 1, taken from EPRI NP-5652. Though not all inclusive, the diagram provides a general feel for the dedication process using this method.

MSFIS REPLACEMENT SYSTEM The critical characteristics are divided into three general categories; Product Information, Physical Attributes, and Performance. EPRI TR-106439 incorporated Product Information in the Physical Attributes categories and added Dependability. Since the MSFIS system may be considered a software based digital system that does not run on a software platform, or a software based hardware driven system, many of the critical characteristics and dedication activities described in EPRI TR- 106439 are applicable and have been incorporated into this Dedication Plan. The critical characteristics of this system are varied enough that all four acceptance methods will be used to verify acceptability. For newer, more complex systems this is not unusual. System and other experts will be used, as applicable, to provide any necessary technical expertise throughout the dedication process. 10CFR21 states:

501 South 11 th Street PHONE: 618-244-6000 TERNATIONAL, INC. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 8 OF 29 "dedication is an acceptance process undertaken to provide reasonable assurance that a commercial grade item to be used as a basic component will perform its intended safety function and, in this respect, is deemed equivalent to an item designed and manufactured under a 10 CFR Part 50, appendix B, quality assurance program. This assurance is achieved by identifying the critical characteristics of the item and verifying their acceptability by inspections, tests, or analyses" As previously stated, a Critical Characteristics Matrix was developed as part of the dedication process. This matrix lists each Critical Characteristic along with its Acceptance Criteria. For each characteristic the matrix also lists the Validation Document(s) and Validation Method(s) which will be used in the dedication process.

Following the matrix a more detailed explanation of each characteristic category and applicable characteristics is included. EPRI TR-106439, 1996, "Guideline on Evaluation and Acceptance of Commercial Grade Digital Equipment for Nuclear Safety Applications", section 4.2 "Guidance on Defining and Verifying Critical Characteristics",

states:

"Translation of design requirements into critical characteristics for a commercial grade item is a key element in the dedication process. It is the link between the technical evaluation, which defines requirements, including hardware, software, human-machine interface, quality and reliability requirements, is an important prerequisite for dedication of a commercial grade item."

A thorough review of Wolf Creek Generating Station Specification J-105A(Q), was performed to generate the Critical Characteristics Matrix, with Acceptance Criteria directly linked to Specification requirements, as applicable.

501 South 11 th Street PHONE: 618-244-6000 INTERNATIONAL, INC. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-971 5DP, REV 2 PAGE 9 OF 29 CRITICAL CHARACTERISTIC MATRIX CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Physical Characteristics:

Configuration-Manufacturer Manufacturer is CS Innovations Nutherm Quality Visual Inspection Assurance Procedure QAP 7.1.00, Model Number Manufacturer Model No. Nutherm Quality Visual Inspection Assurance Procedure QAP 7.1.00, FPGA Flash Version Manufacturer FPGA Flash Nutherm Visual Inspection Revision Number Version Revision No. Procedure, ALS Rack Component Verification, TPS-9062, Rev. 0 Quality of Quality equivalent to qualified NTL-NQI Visual Inspection Workmanship unit Comparison, Nutherm Form 58050-13-7, Nutherm Procedure, ALS Rack Component Verification, TPS-9062, Rev. 0 General Configuration Enclosure same as qualified unit NTL-NQI Visual Inspection Comparison, Nutherm Form 58050-13-7 Nutherm Dedication Plan, WCN-9715DP Mounting Mounting same as qualified unit Nutherm Visual Inspection Qualification Report WCN-9715R 501 South 11 thStreet PHONE: 618-244-6000 jrNuKoThe Mt. Vernon IL 62864 FAX: 618-244-6641.

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 10 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Component Components same as qualified NTL-NQI Visual Inspection Configuration unit Comparison, Nutherm Form 58050-13-7 Nutherm Dedication Plan, WCN-9715DP Subcomponent Subcomponents same as qualified NTL-NQI Visual Inspection Configuration unit Comparison, Nutherm Form 58050-13-7 Nutherm Dedication Plan, WCN-9715DP Interfaces Power 125Vdc Nutherm Direct Test and Dedication Plan, Inspection WCN-9715DP, Nutherm Test Procedure TPS-9064 MSFIS Final Acceptance Test Point to Point Wiring matches wiring diagram Nutherm Direct Test and Continuity Check and Procedure, Inspection Wiring Verification QCI-10.3.30 Proper Switches operate smoothly, see Nutherm Test Direct Test and Bypass/Operate switch Functional section for operational Procedure Inspection operation tests and Acceptance Criteria TPS-9064 MSFIS Final Acceptance Test Human Machine Wolf Creek Specification J- Nutherm Source Source Verification Interface 105A(Q) Verification, SS- Design Review 9715-02 Direct Test and Nutherm Test Inspection Procedure TPS-9064 MSFIS Final Acceptance Test 501 South 11 th Street PHONE: 618-244-6000 TEN9601" LIN Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 11 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Performance Characteristics:

Functional 125 Vdc outputs to Wolf Creek Specification J- Nutherm Test Direct Test and control solenoids to 105A(Q), Procedure Inspection operate valves, verify Section 5.2.1 a, b, e TPS-9064 output logic MSFIS Final Acceptance Test Interchangeability of Wolf Creek Specification J- Nutherm Test Direct Test and components/modules 105A(Q), Procedure Inspection Section 5.2.2 TPS-9064 MSFIS Final Acceptance Test Hot swap capability Wolf Creek Specification J- Nutherm Test Direct Test and 105A(Q), Procedure Inspection Section 5.2.2 TPS-9064 MSFIS Final Acceptance Test Hot swap will not Wolf Creek Specification J- Nutherm Test Direct Test and cause plant transient 105A(Q), Procedure Inspection Section 5.2.2 TPS-9064 MSFIS Final Acceptance Test Response <100 ms Wolf Creek Specification J- Nutherm Test Direct Test and from input step change 105A(Q), Procedure Inspection to output response Section 5.2.3 TPS-9064 MSFIS Final Acceptance Test Nutherm Source Source Verification, SS- Verification, thread 9715-02 audit Momentary input Wolf Creek Specification J- Nutherm Test Direct Test and signal, >100 ms will 105A(Q), Procedure Inspection cause system response Section 5.2.4.a 2) TPS-9064 MSFIS Final Acceptance Test 501 South 11th Street PHONE: 618-244-6000 f*utILer Mt. Vernon 1L 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 12 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD ESFAS contacts NC, Wolf Creek Specification J- Nutherm Test Direct Test and open for response. All 105A(Q) Procedure Inspection other inputs NO, close Section 5.2.4.a 3) TPS-9064 for response MSFIS Final Acceptance Test Output signals: Wolf Creek Specification J- Nutherm Test Direct Test and voltage and current 105A(Q) Procedure Inspection capability, system Section 5.2.4.c 1) TPS-9064 capable of sourcing MSFIS Final adequate current at Acceptance Test min and max voltage Output signal: Wolf Creek Specification J- Nutherm Test Direct Test and switching 40-60 Henry 105A(Q) Procedure Inspection loads at 1.28A Section 5.2.4.c 1) TPS-9064 nominal MSFIS Final Acceptance Test Status outputs: Wolf Creek Specification J- Nutherm Test Direct Test and Outputs per Appendix 105A(Q) Procedure Inspection B Section 5.2.4.c 2) TPS-9064 Output at 125 Vdc if MSFIS Final

[supply fuses for Acceptance Test MV5(6) sat] & [no test in system logic]

Output to status panel capable of 125 Vdc,

<25 mA load Output states: table for Wolf Creek Specification J- Nutherm Test Direct Test and each condition 105A(Q) Procedure Inspection Section 5.2.5.a 1) TPS-9064 MSFIS Final Acceptance Test 501 South 11th Street NUthoerm Mt. Vernon IL 62864.

PHONE: 618-244-6000 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2.

PAGE 13 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Four Commands: Wolf Creek Specification J- Nutherm Test Direct Test and All Close; Close 105A(Q) Procedure Inspection output state for 60 see, Section 5.2.5.a 2) TPS-9064 all 4 valves, then Keep MSFIS Final Closed Acceptance Test ESFAS; 2 of 4, same output as All Close Close; Close output state for associated valve, 60 see delay then Keep Close Open; open output state for associated valve Command priorities in Wolf Creek Specification J- Nutherm Test Direct Test and OPERARE: All Close, 105A(Q) Procedure Inspection ESFAS, Close same Section 5.2.5.b 1) TPS-9064 priority, Open ignored MSFIS Final while above and time Acceptance Test delay not timed out Command priorities in Wolf Creek Specification J- Nutherm Test Direct Test and BYPASS: All Close, 105A(Q) Procedure Inspection Close, ESFAS, Open Section 5.2.5.b 2) TPS-9064 do not cause state MSFIS Final change while in Acceptance Test BYPASS, 501 South 11 th Street PHONE: 618-244-6000 t*Nutherm Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 14 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD BYPASS/OPERATE Wolf Creek Specification J- Nutherm Test Direct Test and mode selection: 105A(Q) Procedure Inspection Independent selection Section 5.2.6.a 1) TPS-9064 for each valve MSFIS Final Acceptance Test Positive action to switch modes In BYPASS no output state change Output state Close, time delay not timed out, will not go to BYPASS Indicating light for Wolf Creek Specification J- Nutherm Test Direct Test and BYPASS 105A(Q) Procedure Inspection Section 5.2.6.a 2) TPS-9064 MSFIS Final Acceptance Test BYPASS initiation Wolf Creek Specification J- Nutherm Test Direct Test and a) Latch outputs 105A(Q) Procedure Inspection b) De-energize status Section 5.2.6.a 3) TPS-9064 output MSFIS Final c) Light BYPASS Acceptance Test mode indication d) Close test contacts described in 5.2.6 Return to OPERATE; Wolf Creek Specification J- Nutherm Test Direct Test and open test contacts, 105A(Q) Procedure Inspection unlatch outputs, Section 5.2.6 .a 4) TPS-9064 extinguish BYPASS MSFIS Final indication, release Acceptance Test status output MSFIS power supplies Wolf Creek Specification J- Nutherm Test Direct Test and will operate on 140- 105A(Q) Procedure Inspection 105 Vdc input power Section 5.6.3.a TPS-9064 MSFIS Final Acceptance Test 501 South 11 th Street PHONE: 618-244-6000 JITENA TNL , NC Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 15. OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD 105-140 Vdc power Wolf Creek Specification J- Nutherm Test Direct Test and supplies, can source 105A(Q) Procedure Inspection sufficient current for Section 5.6.3.b TPS-9064 loads MSFIS Final Acceptance Test Hot swap replacement, two redundant power supplies per rack, one can carry the load Load sharing capability Trouble alarm on loss of a power supply, low "health" Proper operation in all Wolf Creek Specification J- Nutherm Test Direct Test and power supply 105A(Q) Procedure Inspection.

configurations w/o Section 5.6.3.d TPS-9064 spurious trips or loss MSFIS Final of control Acceptance Test Provide wiring harness Wolf Creek Specification J- Nutherm Test Direct Test and 105A(Q) Procedure Inspection Section 5.6.4 TPS-9064 MSFIS Final Acceptance Test, Point to point continuity check and wiring verification QCI 10.3.30 Summary trouble Wolf Creek Specification J- Nutherm Test Direct Test and alarm, NO contact, 105A(Q) Procedure Inspection open to alarm Section 5.6.7.a TPS-9064 MSFIS Final Acceptance Test 501 South 11th Street WNu,oerm Mt. Vernon IL 62864 PHONE: 618-244-6000 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 16 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Alarm conditions Wolf Creek Specification J- Nutherm Test Direct Test and

1. loss DC pwr supply 105A(Q) Procedure Inspection
2. card removed Section 5.6.7.b TPS-9064 Source Verification
3. external test equip MSFIS Final installed Acceptance Test,
4. output sequence Nutherm Source incomplete Verification, SS-9715-02 Indication of trouble Wolf Creek Specification J- Nutherm Test Direct Test and alarm cause 105A(Q) Procedure Inspection Section 5.6.7.c TPS-9064 MSFIS Final Acceptance Test Dielectric test on wire Wolf Creek Specification J- Nutherm Test Direct Test and 105A(Q) Procedure Inspection Section 10.3.2 TPS-9064 MSFIS Final Acceptance Test Apply all possible Wolf Creek Specification J- Nutherm Test Direct Test and input trip 105A(Q) Procedure Inspection combinations in all Section 10.4.3 TPS-9064 states MSFIS Final Acceptance Test Apply manual inputs Wolf Creek Specification J- Nutherm Test Direct Test and 105A(Q) Procedure Inspection Section 10.4.4 TPS-9064 MSFIS Final Acceptance Test Reset Demonstrate the Ability to Reset Nutherm Test Direct Test and Procedure Inspection TPS-9064 MSFIS Final Acceptance Test 501 South 11m Street PHONE: 618-244-6000 f*Nutherm Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 17 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Signal conditioning, Wolf Creek Specification J- Nutherm Review of design, bistable and logic 105A(Q) Dedication Report, input modules, functions Nutherm Source logic function Verification, SS- through Source 9715-02 Verification Review of Vendor Testing at CS.

Innovations Review of Module Level Verification Performance Characteristics:

Environmental EMURFI EPRI Document TR-102323-R2 Nutherm Direct Test and and U.S. Nuclear Regulatory EMIIRFI Report Inspection Commission Regulatory Guide WCN-9715ER 1.180 Seismic IEEE 344-1987. TRS shall meet Nutherm Direct Test and or exceed the RRS of S4000-RP- Qualification Inspection 20 with at minimum a 10% Report margin. Meters shall exhibit WCN-9715R proper operation as outlined in S4000-RP-20.

Mild Environment IEEE 323-1974. 65 0 F to 84TF at a Nutherm Direct Test and Conditions Relative Humidity of 20% to Qualification Inspection 70%. System shall exhibit proper Report operation as outlined in Wolf WCN-9715R I Creek Specification J-105A(Q). I

,jNUtoerm501Mt. Vernon South 11 Street th IL 62864 PHONE: 618-244-6000 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 18 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Abnormal Conditions & Events (ACEs)

Behavior under Correct operation as described in Nutherm Review of Vendor abnormal/faulted Wolf Creek Specification J- Dedication Report, testing including conditions, Vendor 105A(Q) Nutherm Source

  • Board level testing and design Verification, SS- verification, 9715-02 testing of failure detection, redundancy, integrity monitor circuit, debug features, diagnostics
  • Review of FMEA and verification testing
  • Review of hardware architecture, FPGA design review, V&V activities, ALS board test plan
  • Review of Self diagnostic functions, including thread audit Loss and Return of No Loss of Configuration Nutherm Test Direct Test and Power Procedure Inspection TPS-9064 MSFIS Final Acceptance Test Power Over/Under 105-140 Vdc Nutherm Test Direct Test and Voltage Procedure Inspection TPS-9064 MSFIS Final Acceptance Test 501 South 11th Street PHONE: 618-244-6000 f*4911MI, Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 19 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Loss and Return of Correct operation as described in Nutherm Test Direct Test and Input Signals Wolf Creek Specification J- Procedure Inspection (1 or more) 105A(Q) TPS-9064 MSFIS Final Acceptance Test Input Signal Correct operation as described in Nutherm Test Direct Test and Over/Under Range Wolf Creek Specification J- Procedure Inspection (1 or more) 105A(Q) TPS-9064 MSFIS Final Acceptance Test Communication No Loss of Configuration or Nutherm Test Direct Test and Interface Connection Effect on System Operation Procedure Inspection Fault TPS-9064 MSFIS Final Acceptance Test Input Fault/Abnormal No Loss of Configuration or Nutherm Test Direct Test and Input Effect on System Operation Procedure Inspection TPS-9064 MSFIS Final Acceptance Test Dependability Characteristics:

Built-In Quality Quality of Design and Manufacturer maintains a QA Nutherm Commercial Grade Manufacture program that is generally in Dedication Report Survey and/or compliance with a recognized (NI Commercial Source Inspection standard, including as a Grade Survey of including:

minimum: QA CSI). Nutherm Review of CSI Staff/Organization, QA Plans and Quality Plan, QA program Procedures. Evidence the QA Nutherm Source against program was applied in the Verification, SS- relevant production of the procured items. 9715-02 standards Review of CSI Vendor follows a digital procedures for system/software process digital including system/softwar Software development e development, plan for VHDL coding V&V, testing 501 South 11 th Street PHONE: 618-244-6000 fNu5herm Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 20 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD

  • Documented design for each requirements, including module software requirements
  • Thread audits
  • Requirements traceability checking actual
  • Documented software practices for design descriptions QA and
  • Documented V&V plan software
  • Validation testing development and control Evidence the digital
  • Check of the system/software development degree to process has been followed for the which QA latest revision, revision tracking. program and software Documented incorporation of development latest change/revision in process were software/hardware design applied Check of degree to which experience with previous design/revision were applied System Reliability Wolf Creek Specification J- WC/Baseline Analysis Analysis 105A(Q) Engineering SRA Report, Nutherm Dedication Report Hardware Design Evidence the QA program (DO- Nutherm Commercial Grade Process 254) was applied in the hardware Dedication Report Survey and/or design (NI Commercial Source Inspection Grade Survey of CSI)

Configuration Control Configuration control program Nutherm Commercial Grade that includes: Dedication Report Survey and/or

  • Version control of FPGA (NI Commercial Source Inspection design files Grade Survey of
  • Version control of FPGA CSI) design tools fNuther 501 South 11 th Street Mt. Vernon IL 62864 PHONE: 618-244-6000 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 21 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Documented Plan & Procedures Nutherm Commercial Grade Dedication Report Survey and/or (NI Commercial Source Inspection Grade Survey of

________________________CSI)_________

Baseline Maintenance Nutherm Commercial Grade Dedication Report Survey and/or (NI Commercial Source Inspection Grade Survey of CSI)

Change Control Nutherm Commercial Grade Dedication Report Survey and/or (NI Commercial Source Inspection Grade Survey of CSI)

Error-Reporting Process Nutherm Commercial Grade Dedication Report Survey and/or (NI Commercial Source Inspection Grade Survey of CSI)

Software Life Cycle Management Nutherm Source Source Verification Verification, SS- to include 9715-02 evaluation of vendor procedure and implementation Software Established development and Nutherm Source Source Development and control procedures. Verification, SS- Verification, Control 9715-02 Review of Process and Documentation Tool Acceptance Verification and Validation on Nutherm Source Source Methodology tool output performed and Verification, SS- Verification, documented 9715-02 Review of Process and Documentation Failure Modes/Failure A Failure Modes and Effects WC/Baseline Analysis Analysis Analysis (FMEA) is prepared as Engineering Source Verification part of the WC Engineering FMEA Report, Package (EP) process. Nutherm FMEA performed and Dedication Report documented by the vendor at both Nutherm Source component and system level Verification, SS-9715-02 501 South 11 thStreet PHONE: 618-244-6000 INTRNTINA, INC.ý Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 22 OF 29 CRITICAL ACCEPTANCE CRITERIA VALIDATION VALIDATION CHARACTERISTICS DOCUMENT METHOD Problem Reporting Established error-reporting Nutherm Quality Commercial Grade procedures. Seller will also Manual Survey and/or provide reporting to Purchaser. Source Inspection PHYSICAL CHARACTERISTICS Physical characteristics are those characteristics of the item that deal with its construction, materials, shape, form and fit, etc. The critical characteristics classified as physical attributes are determined during the Technical Review and listed on the Critical Characteristics Matrix. The Project Manager evaluates critical physical attributes based on the item's safety function and determines the best method to verify them. Typically, for dedication, these characteristics are compared with a qualified part in the Nutherm International, Inc. Test Specimen Library and/or manufacturers published product information (e.g. drawings, cutsheets, etc.) as applicable. The comparison is documented, then reviewed and evaluated by the Nutherm Engineering department. Any differences between the qualified part and the dedicated item are evaluated with respect to the level that the item is being dedicated to (e.g. Seismic, Mild Environment) and documented either on the Comparison sheet or a Record of Dedication. Through the comparison process, reasonable assurance is gained of the physical similarity between the item to be dedicated and the item previously tested.

MSFIS System critical physical characteristics are listed above. Similarity will be established to the qualified part as well as design documents during the dedication process, with any differences noted and evaluated for impact on qualification by Nutherm Engineering Department.

Product information verification is required to provide reasonable assurance that the item ordered is in fact the item received, as is part of the Physical Characteristic category of Critical Characteristic. This portion of the dedication process includes, but is not limited to, Part Number/Model Number verification and Manufacturer verification. Product information verification is performed and documented at receipt inspection in accordance with Nutherm International, Inc. Quality Assurance Manual No.: QA-N-10179-5 and the applicable approved procedures. Section 1.3.3 of EPRI NP-5652 states; "Part number verification is an integral step in the acceptance of commercial grade items and is included in each of the four acceptance methods. Verification of a part number and the utilization of the acceptance methods in this guideline provide assurance of acceptability.

Since suppliers furnish commercial grade items for general industrial use, they may change the product design or the manufacturing process, and not the part number. These actions are taken without concern for the nuclear end user's design requirements. The methods described in this 501 South 11th Street PHONE: 618-244-6000 INTERNATIONAL, INC. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 23 OF 29 guideline provide various means to accept a commercial grade item without sole reliance upon part number verification."

Because of possible changes by the manufacturer, Product Information alone is an insufficient basis for acceptance of commercial grade items for nuclear safety related applications. This is especially true of complex digital equipment. By combining Product Information verification with the applicable testing, comparisons, etc. of an item's Physical Attributes, Performance characteristics, and Dependability characteristics reasonable assurance of acceptability can be achieved.

Each cabinet of the MSFIS System contains the following which will be verified during the dedication process:

  • 2 ALS Control System Racks; one Main Steam (MS) rack and one identical Feed Water (FW) rack. Each Rack contains the following boards:

o 1 Core Logic board (CLB) o 2 Digital Input boards (IPB) o 1 Solid-State Output board (SOB) o 3 Solid State FET & Sensor Output boards (FSB) o 1 Service & Test board (STB) o 2 Redundant Power Supply Modules (PSU)

  • 1 Assembly panel, with MS and FW components as follows:

o 125V Terminal and Distribution Block o 125V Fuse Blocks for Solenoid Outputs o 125V Fuse Block and Suppression Filter to Power Supplies In addition to Nutherm's normal receipt and visual inspection procedures, each board of each rack will be subject to visual inspection in accordance with Nutherm Procedure TPS-9062, "ALS Rack Component Verification". Each board revision and part number will be recorded along with any other distinguishing marks such as lot numbers, date codes, etc. Software Revision Number for the FPGA logic will be recorded and verified against design documents. Each component on every board will be compared to the manufacturer Bill of Materials (BOM) and Board Layout drawings, as applicable, with any discrepancies noted and addressed in the Dedication Report. Quality of workmanship, such as soldering and overall construction, will be compared with the 501 South 11 th Street PHONE: 618-244-6000 NTERNATIONAL. INC, Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 24 OF 29 quality of the qualification unit with any discrepancies noted and addressed in the Dedication Report.

Component verification against design documents, BOM, and Board Layout drawings provides objective evidence that design control by the manufacturer has been implemented.

PERFORMANCE Though the performance testing outlined in this plan is thorough, it is not intended to imply that testing alone is sufficient to complete the dedication process. The purpose of a thorough test regime is to enhance and support the judgment, reached through a combination of all the dedication activities outlined in this plan, that the items dedicated are suitable for their safety related application.

The Performance section of the dedication plan lists the operational critical characteristics determined during the technical evaluation. Performance characteristics are verified through testing, analysis, or, in the case of UL listings, comparison with manufacturer cutsheets. Performance testing is typically performed at the Nutherm Testing Facility, in accordance with approved procedures. Test results are documented, evaluated by the Nutherm Engineering Department for acceptability, and reviewed by Nutherm QA.

All testing at the Nutherm Test Laboratory is performed by technicians Certified Level II (minimum) in accordance with ANSI N45.2.6 and the requirements of the Nutherm Quality Assurance Program. All quantitative data is taken using measuring and test equipment (M&TE) which is calibrated under the Nutherm Quality Assurance Program, by calibration facilities which operate under Nutherm approved IOCFR50, Appendix B Quality Assurance programs. Standards used in performance of calibration are traceable to NIST. When no national standards exist, the basis for calibration is otherwise documented. In all cases, the accuracy of the M&TE used is equal to or greater than the accuracy requirement specified by the engineering department for the test. The description of the test equipment used is presented on the test data sheets.

Performance testing will be performed on the MSFIS systems to verify proper operation and compliance with the applicable sections of Wolf Creek specification J-105A(Q). A Factory Acceptance Test (FAT), TPS-9064, will be performed on the supplied MSFIS control system. A detailed test procedure for FAT testing has been developed by Nutherm in cooperation with CS Innovations, for approval by Wolf Creek prior to the start of testing. The test procedure was developed based on design documents from CS Innovations as well as WC specification requirements. Actual system response to stimulus is compared to designed response as delineated in design documents through Acceptance Criteria. As part of the FAT abnormal conditions and events testing will be perforned to verify proper system response to abnormal conditions.

501 South 11 t Street PHONE: 618-244-6000 TIONAL, INC. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 25 OF 29 In addition to verifying the performance critical characteristics, thorough testing of the supplied equipment provides objective evidence of design control and built-in quality, adding to the reasonable assurance that the dedicated equipment is suitable for the specified safety related application. The role of additional testing is to supply supporting, documented verification of critical characteristics such as design control and built-in quality, not to replace other dedication processes. For example, Commercial Grade Survey and Source Verification activities are the primary vehicle through which the design control and built-in quality characteristics are verified as described in this plan and recommended in EPRI TR 10643 9.

System Acceptance Testing will be witnessed at CS Innovations as part of the Performance area characteristic verification. Test procedures and performance will be reviewed during the Source Verification. A review of vendor documentation including design tests, logic function testing, and response under abnormal conditions shall be conducted.

DEPENDABILITY The Dependability category of critical, characteristics is described in detail in EPRI TR-106439. These characteristics are difficult to verify through testing and inspection alone.

Because built-in features can have a significant impact on the robustness of electronic devices, dedication activities will continue throughout the design and prototype phases following the life cycle approach. Various verification and validation steps with appropriate documentation will be performed at the different phases of the life cycle as described in the Critical Characteristics Matrix. To gain reasonable assurance in the dependability of the MSFIS system, a combination of inspections, vendor process reviews, verification and validation steps, and product development and documentation review will be used to verify the critical characteristics listed in this plan.

As EPRI TR- 10643 9 recommends, close interaction between the manufacturer and the dedicating entity promotes the development of reasonable assurance that the final product is suitable for the specified safety related application. Nutherm has worked with CS Innovations and WC throughout the design, qualification, and dedication processes through trips to CS Innovations and regular phone conferences. Surveillance activities, including thread audits, were performed to verify and document vendor testing, vendor FMEA performance and documentation, software procedures and implementation, and other critical characteristics as specified in the Matrix.

The following is a more detailed explanation of some of the steps/processes involved in verifying the built-in quality critical characteristics:

Follow-up surveys and source inspections will be performned to verify continued compliance with the CSI QA program.

501 South 11imStreet PHONE: 618-244-6000 INTRNAIONL, NC.Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 26 OF 29 A source inspection will be performed to provide objective evidence that the CSI QA program was applied to the production of the dedicated items.

e A System Reliability Analysis (SRA) was performed under the Wolf Creek (WC)

Quality Assurance program. The SRA report will be reviewed and approved by qualified WC personnel and included in the final Dedication Package. WC will provide documentation and attestation that the SRA critical characteristic has been adequately verified.

  • Surveys and source inspections, as required, will be performed to verify that CSI QA program was applied to the hardware design. The CSI process follows the recommendations of DO-254, "Design Assurance Guidance for Airborne Electronic Hardware". DO-254 describes in detail the Hardware Design Life Cycle and the data which will be developed as evidence of compliance. The surveys and inspections will provide assurance that this process was followed and the appropriate data is available.

0 Surveys and source inspections, as required, will be performed to verify that CSI implements appropriate configuration control. The processes and procedures used by the manufacturer will be evaluated. In particular, version control of FPGA design files and design tools will be verified. Design documents will be verified against delivered equipment as further objective evidence that design control was implemented. The other aspects of configuration control which will be verified include; documented plans and procedures, baseline maintenance, change control, and error reporting processes.

0 Selection of the FPGA and design tools was documented. Said documentation will be included in the final Dedication Report.

  • A Failure Modes and Effects (FMEA) analysis was performed under the WC QA program. The FMEA report will be reviewed and approved by qualified WC personnel and included in the final Dedication Package. WC will provide documentation and attestation that the FMEA critical characteristic has been adequately verified. In addition, the CSI FMEA and safety analysis will be reviewed, including system and component failure analysis documentation.
  • Problem reporting is incorporated in the Nutherm Quality Assurance Manual.

Surveys and source inspections, as required, will be performed to verify that CSI has error-reporting procedures. Conformance to such procedures will be verified.

Thread audits, as recommended in EPRI TR-106439, will be performed as part of the review of CSI documentation and processes. Software development and control, implementation of CSI QA program, and adherence to established coding practices are some of the areas that shall be subjected to thread audits.

501 South 11 t Street PHONE: 618-244-6000 TE ONAL, INC. Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 27 OF 29 VERIFICATION AND VALIDATION Verification and Validation performed by Nutherm will involve several steps and processes. Quality Control Inspections (QCI) in accordance with Nutherm procedures will be performed on the production items. These inspections will include Visual Inspections, Point to Point Continuity Verification, Verification of Specified Parts, as well as a detailed inspection and comparison of board components, BOM's, and board layout drawings. A Final Acceptance Test will be performed in accordance with an approved procedure to verify conformance to purchase order and specification requirements. The Critical Characteristics Matrix lists the performance characteristics which will be verified through testing.

DO-254, "Design Assurance Guidance for Airborne Electronic Hardware", contains detailed requirements for Verification and Validation. Surveys and source inspections will be performed, as required, to verify that the CSI V&V processes, plans, and implementation conform with the requirements of DO-254.

501 South 11 th Street PHONE: 618-244-6000 f*4ZL7,*' Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 28 OF 29 Figure 1. Generic Process for acceptance of Commercial Grade Items Used in Safety Related Applications, Per EPRI NP-5652 Identify Required Items by Means of Technical Evaluation NO Teficiency reporting responsibility accepted.

501 South 11* Street PHONE: 618-244-6000

~N1therm Mt. Vernon IL 62864 FAX: 618-244-6641

DEDICATION PLAN WCN-9715DP, REV 2 PAGE 29 OF 29 FIGURE 2 Method 1 - Special Tests and Inspections 501 South 11 th Street PHONE: 618-244-6000 f*Njtherm Mt. Vernon IL 62864 FAX: 618-244-6641

LETTER-OF TRANSMITTAL Transmittal No. 127431 Pagel of I SUBMITTED TO: DATE: CLIENT REFERENCE Gregg Clarkson 08/30/07 .734527 Wolf Creek Nuclear Operating Corp.

P.O. Box 411 Burlington, KS 66839 SHIPPED VIA NUTHERM REF. NO. PROJECT Email qrclark)wcnoc.com WCN-9715 Wolf Creek SUBMITTAL COPY ITEM DESCRIPTION DOCUMENT NO./REV. CODE QUANTITY 1 Nutherm Dedication Plan WCN-9715DP, Rev. 2 1 1 COMMENTS:

Receipt Acknowledged By aýý_ Date: -?________

SUBMITTAL CODES

1) APPROVAL 2) INFORMATION 3) RECORD Tnc. 501 South ~ Mt. Vernon, IL 62864 International, Inc.

NUTHERM International, NUTHERM 501 South I I'h Street Mt. Vernon, IL 62864

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