ET 08-0008, Additional Information Regarding Main Steam and Feedwater Isolation System (Msfis) Controls Modification

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Additional Information Regarding Main Steam and Feedwater Isolation System (Msfis) Controls Modification
ML080390312
Person / Time
Site: Wolf Creek Wolf Creek Nuclear Operating Corporation icon.png
Issue date: 01/31/2008
From: Garrett T
Wolf Creek
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
ET 08-0008
Download: ML080390312 (26)
v • d • e


Text

WAl CREEK

'NUCLEAR OPERATING CORPORATION Terry J. Garrett January 31, 2008 Vice President, Engineering ET 08-0008 U. S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, DC 20555

Reference:

1)

Letter ET 07-0004, dated March 14, 2007, from T. J. Garrett, WCNOC, to USNRC

2)

Letter ET 07-0022, dated June 15, 2007, from T. J. Garrett, WCNOC, to USNRC

3)

Letter ET 08-0004, dated January 18, 2008, from T. J. Garrett, WCNOC, to USNRC

Subject:

Docket No. 50-482: Additional Information Regarding Main Steam and Feedwater Isolation System (MSFIS) Controls Modification Gentlemen:

Reference 1 provided a license amendment request that proposed revisions to' Technical Specification (TS) 3.3.2, "Engineered Safety. Feature Actuation System.(ESFAS)

Instrumentation," TS 3.7.2, "Main Steam Isolation-Valves (MSIVs);'

and TS 3.7.3, "Main Feedwater Isolation Valves (MFIVs)." Reference 1 proposed. changes to these specifications based on a planned modification to replace the MSIVs and associated actuators, MFIVs and associated actuators, and replacement of the Main Steamr and Feedwater Isolation System (MSFIS) controls.

Reference 2 provided Wolf Creek Nuclear -Operating Corporation's (WCNOC) response to a request for supplemental information. WCNOC's response to Question 17, item B, indicated that the analysis of factory acceptance testing. activities verifying that the procedure(s) will test the items required by the test plan, and the results showing that the tests demonstrated that the system meets the requirements would be captured in Revision 2 of the System Verification and Validation Report. Reference 3 committed to provide Revision 2 of the System Verification and Validation Report and is provided in Enclosure I. The System Verification and Validation Report incorporates the Implementation and Test Analysis Report.

Revision 2. builds on previous Revisions 0 and 1. An updated Requirements. Traceability Matrix will be provided separately as discussed in the ET 08-0004 letter. Revision 2 discusses the recent change in the procurement structure where the equipment will be procured as safety related from CS Innovations.

PO. Box 411 / Burlington, KS 66839 / Phone: (620) 364-8831 An Equal Opportunity Employer M/F/HC/VET k

ET 08-0008 Page 2 of 3 The supplemental information provided in the Enclosure does not impact the conclusions of the No Significant Hazards Consideration provided, in Reference 1. In accordance with 10 CFR 50.91, a copy of the submittal is being provided to the designated Kansas State official.

This letter contains no commitments. If you have any questions concerning this matter, please contact me at (620) 364-4084, or Mr. Richard D. Flannigan at (620) 364-4117.

Sincerely, Terry J. Garrett TJG/rlt Enclosure cc:

E. E. Collins (NRC), w/e T. A. Conley (KDHE), w/e J. N. Donohew (NRC), w/e V. G. Gaddy (NRC), w/e B. K. Singal (NRC), w/e Senior Resident Inspector (NRC), w/e

ET 08-0008 Page 3 of 3 STATE OF KANSAS

)

SS COUNTY OF COFFEY )

Terry J. Garrett, of lawful age, being first duly sworn upon oath says that he is Vice President Engineering of Wolf Creek Nuclear Operating Corporation; that he has read the foregoing document and knows the contents thereof; that he has executed the same for and on behalf of said Corporation with full power and authority to do so; and that the facts therein stated are true.

and correct to -the best of his knowledge, information and belief.

Terry J.1 rett Vice President Engineering SUBSCRIBED and sworn to before me this -

day of \\JOn.

rj(i

,2008.

GAYLE SHEPHEARD1 Notary (public Notary Public - State of Kansasl My Appt. Expires 7/,2 L//20)1 Expiration Date q/i97/

2 /1 /

/

/

Enclosure I to ET 08-0008 System Verification and Validation Report, Revision 2

MAIN STEAM & FEEDWATER ISOLATION SYSTEM (MSFIS)

CONTROLS REPLACEMENT F,

SYSTEM VERIFICATION AND VALIDATION REPORT REVISION 2 PROJECT MANAGER - GREGG CLARKSON MANAGEMENT SPONSOR PATRICK GUEVEL EXECUTIVE SPONSOR TERRY GARRETT Wolf Creek Nuclear Operating Corporation PO Box 411 1550 Oxen Lane, NE Burlington, KS 66839 Revision 2 1/29/2008 Page 1 of 22

Table of Contents 1

Introduction

.........................................................................................................................3 P U R P O S E.......

......................................................................................................................... 3

1.

REFERENCE MATERIAL........................................................................................

............ 4

2.

VERIFICATION AND VALIDATION OVERVIEW......................................................................

5 2.1.

ORGANIZATION..........................................................................................................

5 2.1.1.

V&V Staffing:...........................................*....................................................................

8 2.2.

TASKS AND RESPONSIBILITIES.....................................7-.....

8 2.3.

TOOLS, TECHNIQUES AND METHODOLOGY.....................................................................

9

3.

LIFE CYCLE V&V.............................................................................................................

11 3.1.

MANAGEMENT..........................................................................................................

11.

3.2.

SYSTEM REQUIREMENTS V&V.....................................................................................

11 3.3.

HARDWARE REQUIREMENTS V& V................................................................................

12 3.4.

DESIGN PHASE V&V.........................................:..........................................................

14 3.5.

IMPLEMENTATION and TEST PHASE V&V.......................................................................

19 3.5.1.

Implementation Phase.....................................................................................................

19 3.5.2.

Test Phase..................................................................................................................

21

4.

V&V

SUMMARY

22 Revision 2 1/29/2008 Page 2 of 22

Li -..

tr...io PURPOSE The purpose of the System Verification and Validation Report is to document the verification and validation processes and procedures that were used by Wolf Creek Nuclear Operating Company (WCNOC) to assure that the Advanced Logic System Main Steam and Feedwater Isolation System (ALS MSFIS) controls being developed meet the requirements for a safety related Class 1E qualified nuclear power plant safety system.

The System Verification and Validation Report shall being issued in four (4) phases, as follows:

Revision 0 -- Requirements Analysis Report Revision 1 -- Design Analysis Report Revision 2 -- Implementation and Test Analysis Report Revision 3 -- Validation Test Report This is Revision 2, the Implementation and Test Analysis Report.

The System Verification and Validation Report is a living document that is prepared and updated periodically during the course of the project development.

Each phase of the project, e.g., System Requirements Phase, Hardware Requirements Phase, Design Phase, and others, shall be covered by a subsection that documents in detail the V&V efforts during that phase, and the results thereof, including anomalies discovered and their resolution and consequent rework, reverification and revalidation. The documentation that each phase has been completed in full compliance with the requirements of that phase with respect to the specifications shall be included or specifically referenced from among the other required project documentation. The final report will consist of these subsections, together with subsections providing an overview and a summary of the entire V&V effort. The Requirements Traceability Matrix shall be included as an appendix to the final System Verification and Validation Report. The format of the report will generally follow the outline below:

1.

Purpose/Applicability/Limits/Exclusions of this System Verification and Validation Report

2.

Summary/Overview of the Project V&V effort.

3.

System Requirements Phase V&V

4.

Hardware Requirements Phase V&V,

5.

Design Phase V&V Revision 2 1/29/2008 Page 3 of 22

6.

Implementation Phase V&V (including Pre-Production Test Report)

7.

Test Phase V&V (including Final Acceptance Test Report)

8.

Installation and Checkout Phase V&V The System Verification and Validation Report will supplement the Nutherm Qualification Test Report (QTR) by providing the details of the qualification of the system.

The System Verification and Validation Report shall be prepared by the V&V Engineer, and approved by the ALS MSFIS Project Manager.

1.

REFERENCE MATERIAL 1.1 Binding documents applicable to the Verification and Validation Plan for this project are:

1.1.1 Wolf Creek Nuclear Operating Company (WCNOC) Specification J-105A(Q) 1.1.2 CMP - Configuration Management Plan for Class 1E Qualified ALS MSFIS 1.1.3 WCNOC Procedure AP 05F-001 - Design Verification 1.1.4 WCNOC Procedure AP 05-002 - Dispositions and Change Packages 1.1.5 WCNOC Procedure AP 05-005-Design, Implementation Configuration Control of Modifications 1.1.6 MSFIS V&V Report, CSI document 6101-00200 1.1.7 Qualification Test Report, Nutherm document WCN-9715R Revision 2 1/29/2008 Page 4 of 22

2.

VERIFICATION AND VALIDATION OVERVIEW 2.1. ORGANIZATION This section describes the organization for design/development and V&V of the subject system.

The project includes three independent groups, under the oversight of the ALS MSFIS Project Manager and WCNOC Engineering:

1. WCNOC Engineering - responsible for the design and implementation of modifications at WCGS using established WCNOC processes and procedures (AP 05-002, Design Change Process). As a part of the established processes and procedures, an independent V&V of the Design Change Package is performed by a qualified WCNOC Engineer.
2.

Design Contractor/Class 1E Controls Supplier - responsible for the design, development, integration, and final delivery of the product. For this project, CS Innovations (CSI) is providing this function.

3.

Qualification and Quality Oversight Contractor - responsible to provide both oversight and direct actions to independently ensure that the requirements on qualification of safety related hardware for the Class IE system, including its performance, integration, configuration control, and documentation, are satisfied. Nutherm International (NI) performed this function.

4.

V&V Consultant - responsible to provide independent oversight and direct actions to ensure that the V&V requirements for a Class 1E system are satisfied. Baseline Engineering is providing this function as staff augmentation to WCNOC Engineering.

Revision 2 1/29/2008 Page 5 of 22

4 I

Design Change Process K,

/

WCNOC Engineering t

t

  • b

(

CNCStaffAugmentation)*ii:

  • ,:.'i?:i Design Contractor/Class

,1E Supplier~

(C(s lnnovatiorisY Qualification and, Quality Oversight Contractor (Nutherm International) I

/

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=---

Figure 1-- ALS MSFIS PROJECT ORGANIZATION CHART Subsequent to the issue of System Verification and Validation Report Revision 1 (8/31/07), WCNOC implemented a revised procurement structure for the MSFIS equipment. As noted above, CSI is now the Class 1E supplier, and NI's role for the ALS MSFIS project is to provide environmental qualification (EQ) and supplemental, or "augmented",

quality oversight. This results in some duplication of quality efforts on the project. CSI has independently performed some additional EMC testing (informally) and has also performed an additional Factory Acceptance Test (FAT).

These activities are documented in the MSFIS V&V Report (ref. 1.1.6).

Prior to implementation of the new procurement structure WCNOC performed a Part 50 Appendix B audit of CSI.

This performance based supplier audit focused on the supplier's in-process activities that are needed to reach a conclusion about whether items produced by the supplier's process will perform their intended function. This audit relied, in part, on the confirmatory acceptance testing that was performed by NI. The audit results concluded that the CSI Quality Assurance Program was well implemented and satisfies the requirements of 10 CFR 50 Appendix B.

WCNOC's audit of CSI's 10 CFR 50 Appendix B Quality Assurance Program and performance of the independent reviews and qualification testing by NI, combined with WCNOC quality and engineering personnel oversight surveillance activities, provided the basis for the approval of CSI's 10 CFR 50 Appendix B Quality Assurance Program to supply WCNOC with safety related material.

Figure 2 provides a timeline depicting the activities associated with the ALS MSFIS controls.

Revision 2 1/29/2008 Page 6 of 22 Revision 2 1/29/2008 Page 6 of 22

ALS MSFIS Controls - Vcndor QA Timcinc IONOOIG H-CS INNOVATIONS OA PROGRAM T

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.FlIIIPkFNT Acti vitiez 1 UTHERM OA PROGRAM IDESIGN REVIEWS AND VENDOR SURVEYS]

S-Figure 2 Revision 2 1/29/2008 Page 7 of 22

2.1.1. V&V Staffing:

2.1.1.1. V&V Engineer, having broad background and experience in the design, development, test and operation of nuclear power plant instrumentation and control systems, and the standards and practices in this discipline, particularly regarding the experience in applying digital computer technology in these applications.

The V&V Engineer shall perform and/or direct the performance of the V&V activities of the project.

2.2. TASKS AND RESPONSIBILITIES This section identifies the responsibilities of specific individuals and organizations within the framework of the System Verification and Validation Report.

2.2.1. Proiect Manager Responsibilities tc \\13 "4.3.1 - Project Manager Responsibilities}

The ALS MSFIS Project Manager is responsible either personally, or through the actions of others, for the performance of the entire ALS MSFIS Project, including all aspects of design, development, manufacture, testing, and shipping.

The following elements of V&V related activities are included in these responsibilities:

Prepare System Specification Prepare Project Plan Coordinate subcontracted design, qualification and test 2.2.2. Verification and Validation Engineer Responsibilities The V&V Engineer is an independent individual that is responsible to supervise and/or perform the System V&V Plan including the documentation thereof. Responsibilities include:

Perform and/or supervise verification and validation activities for each project phase.

Prepare the following plans:

System V&V Plan MSFIS Configuration Management Plan (CMP)

Revision 2 1/29/2008 Page 8 of 22

Prepare the Following Documents:

System Verification and Validation Report Requirements Traceability Matrix (RTM)

System Reliability Analysis (SRA)*

Failure Modes and Effects Analysis (FMEA)*

  • The SRA and FMEA, although not "traditional" V&V functions, are being performed by the V&V engineer. The reports will be included in the System Verification and Validation Report Revision 3 as significant factors in the total system V&V process.

2.2.3. Qualification and Quality Oversight Contractor Responsibilities The following elements of V&V related activities are included in these responsibilities:

Prepare the following plans:

Qualification Plan Dedication Plan (Note: The Qualification and Quality Oversight Contractor (NI) was responsible for all aspects of the Class 1E qualification as the ALS MSFIS Controls procurement was originally structured.

The Design Contractor and Class IE Controls Supplier (CSI) is now providing the equipment under their own Appendix B program, so some of the dedication activities have been re-iterated.

Reference 1.1.6 provides details of this.)

Prepare the Following Procedures:

Seismic Test Procedure EMC Test Procedure 2.3. TOOLS, TECHNIQUES AND METHODOLOGY 2.3.1. Tools Revision 2 1/29/2008 Page 9 of 22 Revision 2 1/29/2008 Page 9 of 22

One special tool is used in the V&V process, as follows:

1)

A software tool (IBM Rational Pro) for tracking: system requirements from the original specification through the various design documents, and generating the Requirements Traceability Matrix.

2.3.2. Techniques and Methodologies The fundamental methodology is to verify and document that each phase of the system development life cycle resulted in a product that satisfies the requirements for that phase. It must be proven that all elements of the design conform to the requirements. Further, it must be demonstrated that the integrated product performs all of the required functions, with no unintended functions.

To assure adequacy of the design and to facilitate the performance of the V&V process the following steps were taken:

a.

Detailed, well defined requirements were established and formatted to facilitate verification that each requirement is satisfied, e.g., to facilitate testing and tracking.

b.

To the maximum practicable extent, requirements were specified in well defined mathematical language, such as logic diagrams, state tables, or other unambiguous forms.

c.

A Requirements Traceability Matrix is maintained to facilitate verification that the requirements were correctly propagated forward through the design, testing and validation steps of the development process, and so that validation at each phase of the development process is related specifically to these requirements.

d.

Testing is defined and derived from the established requirements.

e.

Testing results are well documented.

f.

Configuration management are enforced.

g.

Changes in requirements are controlled through a process of approval, documentation, and verification and validation commensurate with the scope and criticality of the changes.

h.

Software that has been procured for use in design and/or testing shall be controlled during all phases of MSFIS development.

i.

Procedures assure configuration control, including verification that the configuration used during testing is the same as that used for the final system.

Revision 2 1/29/2008 Page 10 of 22

3.

LIFE CYCLE V&V The life cycle used in this project follows the "waterfall" model and includes the following phases:

1)

System Requirements Phase

2)

Hardware Requirements Phase

3)

Design Phase

4)

Implementation Phase

5)

Test Phase

6)

Installation and Checkout

7)

Operation and Maintenance 3.1. MANAGEMENT The management of the V&V process for this project entails a close working relationship between the V&V Engineer and the ALS MSFIS Project Manager, to define the "fine structure" for the V&V work within the framework defined in this document.

The V&V report (this document) is prepared and maintained as a living document during the life of the project by updating and adding material as each phase of the project is completed and any necessary iterations are performed.

3.2. SYSTEM REQUIREMENTS V&V 3.2.1. Overview System requirements were established by WCNOC in Specification J-105A(Q). CSI used this document to basethe preparation of the conceptual design. One V&V step was taken in this phase:

1)

Critical review of J-1 05A(Q) and resolution of comments and questions deriving there from.

The principal V&V method used in this phase was the critical review of the WCNOC specification followed by discussions to resolve any comments or questions. The Requirements Traceability Matrix was initiated to provide a formalized database that provides item number by item number correlations.

Particular attention was given to assuring that the requirements are amenable to demonstration by test of the completed system. Approval was obtained from the CSI Lead Design Engineer, Qualification and Quality Oversight Contractor (NI), V&V Engineer and the Project Manager following resolution of all comments resulting from the System Requirements Verification. The criteria for satisfactory completion of this phase was the agreement by all parties that closure was achieved on all comments and that each individual technical requirement could be demonstrated through either test or analysis.

Revision 2 1/29/2008 Page I11 of 22

3.2.2. Inputs/Outputs The iMut for this phase was the initial J-105A(Q) specification, Revision 1.

The outpu for this phase was the resolution of comments, and issuance of Revision 2 of the J-105A(Q) specification.

3.3. HARDWARE REQUIREMENTS V&V The hardware requirements phase consisted of one step:

1)

The preparation of the System Requirements Document (SRD, CSI Document 6101-00002, "MSFIS System Specification, Wolf Creek Generating Station").

The SRD provides a structured delineation of the system requirements contained in the J-105A(Q) specification that are satisfied by the design, and the manner and structure in which the design will function to satisfy those requirements. The SRD addresses:

a.

Process inputs, including test inputs.

b.

System logic required for operation of the MSFIS.

c.

Process outputs, including ranges, accuracies, update interval, and human factors considerations of the operator interface.

d.

Initialization requirements such as initial values and start-up sequence.

e.

Logic for response to detected failures.

f.

Operator interfaces (control panels, displays).

g.

Automated in-service test and diagnostic capabilities.

h.

Timing requirements for all time dependent events, including overall system requirements.

i.

Limitations on processing time.

Revision 2 1/29/2008 Page 12 of 22

j.

Security requirements such as passwords.

k.

Design features that provide administrative control of all devices capable of changing the content of stored setpoints and logic.

1.

Initialization requirements such as power-up and power-down.

m.

Design features for the detection of system failure.

n.

Manually initiated in-service test or diagnostic capabilities.

o.

Human factors engineering design features encompassing operator interfaces associated with operation, maintenance, and testing.

p.

Mechanical and electrical interfaces with existing systems and structures.

q.

Design features necessary to assure satisfaction of the seismic and electromagnetic interference design requirements for the system.

The SRD includes all of the technical requirements of the project in a form that facilitates tracking back to the statements of the J-105A specification, and forward to the succeeding phases of the development program.

3.3.1. Verification and Validation Tasks The V&V tasks for the requirements phase consisted of independent reviews of the documents prepared in this phase against the WCNOC J-105A(Q) specification.

All questions, comments or anomalies found during the reviews were documented and resolved before proceeding to the design phase of the development process.

3.3.2. Methods and Criteria The Requirements Traceability Matrix was updated to confirm that the complete set of J-105A specification requirements were covered by the SRD. This step included:

1.

Tracing the requirements to the system requirements.

2.

Review of identified relationships for correctness, consistency, completeness, and accuracy.

Revision 2 1/29/2008 Page 13 of 22

3.

Review to assure the requirements are testable.

4.

Assessment of how well system requirements were satisfied, and identification of key performance and critical areas of the design.

3.4. DESIGN PHASE V&V The Tasks for the Verification and Validation of the design phase of the development process for the ALS MSFIS consisted of several activities as follows:

Review, approval, and issue of the CSI Documents 6101-00002, MSFIS System Specification, Wolf Creek Generating Station prepared by the design team to satisfy the requirements of the WCNOC J-105A(Q)

Specification. Revision 3 of J-105A(Q) was issued on 6/29/07. This revision resolved several issues that were raised during the design phase and represents the "final" specification version moving forward from the Design Phase.

Preparation and issue by the Design Contractor /Class 1E Controls Supplier of the following documents:

ALS Level 2 FPGA Specification 6000-00002 - ALS-101 Level 2 Hardware Specification S

0 6000-00003 -ALS-201 Level 2 Hardware Specification 6000-00004 -ALS-301 Level 2 Hardware Specification 6000-00005 -ALS-401 Level 2 Hardware Specification 6000-00006 -ALS-411 Level 2 Hardware Specification 6000-00007 -ALS-905 Level 2 Hardware Specification These specifications were issued by the Design Contractor /Class 1E Controls Supplier and represent the detailed board designs for the ALS MSFIS.

Revision 2 1/29/2008 Page 14 of 22

Review, approval, and issue of drawings including:

4101-008 Bill of Materials and Assembly

Drawing, ALS Backpanel 4101-007 Schematic, Backpanel, MSFIS 4101-010 Bill of Materials and Assembly Drawing, ALS-101 4101-009 Schematic, ALS-101 4101-012 Bill of Materials and Assembly Drawing, ALS-201 4101-011 Schematic, ALS-201 4101-018 Bill of Materials and Assembly Drawing, ALS-201 Bypass Switch Board 4101-017 Schematic, ALS-201 Bypass Switch Daughterboard 4101-004 Bill of Materials and Assembly Drawing, ALS-301 4101-003 Schematic, ALS-301 4101-006 Bill of Materials and Assembly Drawing, ALS-401 4101-005 Schematic, ALS-401 4101-002 Bill of Materials and Assembly Drawing, ALS-411 4101-001 Schematic, ALS-411 4101-014 Bill of Materials and Assembly Drawing, ALS-905 4101-013 Schematic, ALS-905 4101-035 Drawing, Assembly Panel, SA075A 4101-036 Bill of Material and Wirelist, Assembly Panel, SA075A 4101-037 Drawing, Assembly Panel, SA075A 4101-038 Bill of Material and Wirelist, Assembly Panel, SA075A 4101-049 Drawing, SA075A, Vendor Wiring 4101-050 Drawing, SA075B, Vendor Wiring 4101-019/4101-021 Drawing, WC-MSFIS Cable, Cxxi (MS/MF) 4101-020/4101-022 Bill of Material and Wirelist, WC-MSFIS Cable, Cxxi 4101-023/4101-025 Drawing, WC-MSFIS Cable, Cxx2 (MS/MF) 4101-024/4101-026 Bill of Material and Wirelist, WC-MSFIS Cable, Cxx2 4101-027/4101-029 Drawing, WC-MSFIS Cable, Cxx3 (MS/MF) 4101-028/4101-030 Bill of Material and Wirelist, WC-MSFIS Cable, Cxx3 Revision 2 1/29/2008 Page 15 of 22

4101-031/4101-033 Drawing, WC-MSFIS Cable, Cxx4 (MS/MF) 4101-032/4101-034 Bill of Material and Wirelist, WC-MSFIS Cable, Cxx4 4101-065 Drawing, MSFIS Logic Overview 4101-061 Drawing, SA075A MS One Line Drawing 4101-062 Drawing, SA075A MF One Line Drawing 4101-063 Drawing, SA075B MS One Line Drawing 4101-064 Drawing, SA075B MF One Line Drawing 9715-SA-71294-D Mounting Platform MSFIS Rack Sub-Assembly 9715-OD-71217-D MSFIS Cabinet Outline Dimensional 9715-SA-71216-D MSFIS Cabinet Shop Assembly 9715-PP-71215-D Mounting Platform Piece Parts Preparation of the Test Procedures prepared by the Qualification and Quality Oversight Contractor, needed to accomplish the Implementation and Test Phases of the development process, including the following:

Baseline Test Procedure FPGA Verification Procedure TPS-9059R1 9715-EI-02 Review and approval of the Final Acceptance Test Procedure by the Qualification and Quality Oversight Contractor, to confirm that all set(s) of the system are identical to the first set and to confirm that the performance requirements are satisfied.

Final Acceptance Test 9715-TPS-9064 Revision 2 1/29/2008 Page 16 of22 Revision 2 1/29/2008 Page 16 of 22

Review and approval of~the ElectromagneticT7adl Frequency Interference Test Procedure prepared by the Qualification and Quality Oversight Contractor, to confirm that the system will perform satisfactorily in the EMI environment typical of a power plant control room, and will not affect other equipment installed there.

EMC Test Procedure 9715-EMC-01 Review and approval of the Seismic Test Procedure prepared by the Qualification Contractor, to confirm that the system will remain functional during and after the seismic disturbances specified for the plant site.

I Seismic Test Procedure S-128P The Qualification and Quality Oversight Contractor issued the Dedication Plan for WCNOC review and approval. The Dedication Plan defines the ALS MSFIS Critical Characteristics and the applicable processes and standards to be applied in the commercial grade dedication of the equipment, in accordance with EPRI NP-5652. Review comments were incorporated and a final Dedication Plan was issued.

Dedication Plan WCN-9715DP The Qualification and Quality Oversight Contractor completed a number of commercial grade surveys which included review of the Design Contractor /Class 1E Controls Supplier's design process / design architecture and found the controls and process to be adequate. The dates of the surveys are provided on the timeline diagram in Figure 2. The source surveillance and commercial grade survey were based on review of objective evidence of work performed by the Design Contractor /Class 1E Controls Supplier on the ALS MSFIS project. The Qualification and Quality Oversight Contractor will include a detailed report of their reviews in the final Dedication Report.

(Note: As discussed in section 2.2.3, the Qualification Contractor (NI) was responsible for all aspects of the Class 1E qualification as the ALS MSFIS System procurement was originally structured.

The Design Contractor (CSI) is now providing the equipment under their own Appendix B program, so some of the dedication activities have been re-iterated. The dedication activities provided by NI will be utilized at WCNOC as augment quality items and reports.)

The Design Contractor /Class lE Controls Supplier issued a Safety Assessment of the ALS MSFIS. The Safety Assessment analyzes the Functional Failure Paths of the MSFIS and from this analysis determines the safety assurance levels for major components. The safety assessment provides both a qualitative and quantitative analysis of the ALS MSFIS reliability and availability.

MSFIS Safety Assessment 6101-00006 Revision 2 1/29/2008 Page 17 of 22

The Methods employed in the Verification and Validation of the Design Phase consisted principally of visual review of documents and drawings against the preceding phase Outputs and the engineering experience of the reviewers, and the writing of original documents to cover the required testing. The Criteria for acceptance were the projections of the experienced personnel performing the work that the documents being reviewed and prepared would meet the requirements of the Wolf Creek specification and work properly after installation irrespective of the specification requirements.

The Inputs for the Verification and Validation of the Design Phase were the Wolf Creek J-105 specification and the CSI ALS Level-i System Specification (6000-00000). The Outputs of the Verification and Validation of the Design Phase were the approvals of the several documents and drawings, and the approved test procedures. No Iterations affecting the outputs of previous phases were required, affecting either the Conceptual Design or Requirements Phases.

Revision 2 1/29/2008 Page 18 of 22

  • i* i 3.5. IMPLEMENTATION and TEST PHASE V&V 3.5.1. Implementation Phase The implementation phase included the assembly of the first set of hardware, preliminary tests of operability, performance of the Preproduction Test by CSI, and performance of the Seismic and EMC tests by NI. The assembly and testing of the remaining production units was completed following satisfactory completion of the qualification testing.

3.5.1.1. Verification and Validation Tasks The V&V Engineer worked closely with the design and qualification teams throughout this phase to ensure that the project objectives, as defined in the various levels of specifications were satisfied. The V&V Engineer verified that anomalies were being recognized and resolved in accordance with controlled processes.

3.5.1.2. Methods and Criteria The implementation phase consisted of the performance of the following tests:

Seismic Test in accordance with Nutherm Seismic Test Procedure S-128P EMC Test in accordance with Nutherm EMC Test Procedure 9715-EMC-0 1 Preproduction Test in accordance with CSI ALS Board Test Plan 6000-00008 and MSFIS System Test Plan 6101-00004 3.5.1.3. Inputs/Outputs Inputs to the V&V effort for this phase were the system design documents, the hardware, the Pre -

Production Test Procedure, the Seismic Test Procedure, and the EMC Test Procedure.

Outputs of the V&V effort for this phase were updates to the previously prepared V&V documentation, test procedure reviews and approvals, changes to the test procedures required as a result of any iterations initiated in this phase, and the test reports.

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Details of the Implementation Phase tests are as follows:

The initial issue of the seismic test procedure was S-128P Rev.0, issued on 11/15/06. S-128P Rev.1 was issued on 12/22/06 for WCNOC review and comment, and S-128P Rev.2 was issued on 1/8/07 to incorporate the approval comments.

The seismic test was performed on 1/11/07 at Wyle Laboratories. The seismic testing was completed successfully as documented in NI Qualification Report WCN-9715R Rev,0.

The initial issue of the EMC test procedure was 9715-EMC-01 Rev.0, 11/26/06. Subsequently, Rev.1 was issued on 11/28/06 to incorporate clarifications and to add a "Safety Function Actuation Test". 9715-EMC-01 Rev.2 was issued on 12/04/06 to include CSI equipment grounding recommendations. Rev.3 was issued on 12/14/06 to add a note regarding the rationale for power lead surge withstand level tests. The final EMC test procedure revision, 9715-EMC-01 Rev.4 was issued on 12/19/06 to add test levels for the 1EC 61000-4-4 Ring Wave Immunity Test, add a re-test of the IEC 61000-4-4 Electrical Fast Transient/Burst Immunity Test, and to add re-test, pre-test, and post-test verification sheets.

CSI conducted several EMC "pre-tests" at a local National Technical Systems subsidiary in Phoenix, AZ from August 2006 through November 2006. These tests were performed to validate the ALS board designs against NRC RGI.180 / EPRI TR-102323 Revision 2 and also EPRI TR-102323 Revision 3, prior to formal testing.

Formal EMC testing was performed 12/07 at Elite Electronic Engineering. Testing was satisfactorily completed, however anomalies that arose during IEC 61000-4-3 (Radiated Immunity, 26MHz to 10Ghz),

IEC 61000-4-4 (Electrical Fast Transients), and IEC 61000-4-5 (Surge Immunity) resulted in minor modifications (grounding arrangement and surge suppression design) to the test specimen to achieve a satisfactory result. These modifications are detailed in the Nutherm EMC Test Report, WCN-9715ER Rev.0, dated 2/16/07 and in the following CSI Engineering Change Notices (ECN's):

ECN 101-0000 - Modification to ALS-411 boards due to MOV early clamping during Surge testing ECN 101-0001 - Modification to ALS-905 boards due to capacitor early clamping during Surge testing ECN 101-0002 - Modification to MSFIS Assembly Panel to avoid fuses blowing during surge testing The ECN's are listed in Reference 1.1.6.

EMI qualification testing was completed successfully as documented in NI Qualification Report WCN-9715R Rev.0. CSI revised the Bills of Material (BOM's) and equipment drawings to incorporate the surge suppression and grounding changes made during EMI qualification, and these changes were reflected in the production equipment.

The preproduction test was completed satisfactorily on the qualification unit, and the test report is contained in the CSI equipment travelers. Additional details are provided in Reference 1.1.6.

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The Design Contractor /Class 1ECoritrols Supplier completed Field Programmable Gate Array (FPGA) programming and V&V activities (referi to Reference 1.1.6), prepared the preproduction unit, completed preproduction testing and completed the production units The Qualification and Quality Oversight Contractor prepared the Seismic Test Procedure and the EMC Test Procedure and completed the seismic and EMI qualification.

3.5.2. Test Phase The test phase of this project consisted entirely of performing the Factory Acceptance Test (FAT) on each set of deliverable equipment.

3.5.2.1. Verification and Validation Tasks The V&V responsibility for this phase consisted of reviewing the FAT procedure and the FAT results.

3.5.2.2. Methods and Criteria The Test Phase consisted entirely of performance of the FAT. Criteria for satisfactory completion of this phase were that the performance of each hardware set exactly satisfied the required performance set down in the FAT procedure, and that any anomalies were resolved, and that any rework or iterations were completed thoroughly and documented fully.

3.5.2.3. Inputs/Outputs The test was performed in accordance with CSI procedure 6101-00004 "MSFIS System Test Plan". Rev.0 of the FAT procedure was issued on 10/13/06. Subsequent revisions were issued to incorporate additional system features and changes to the test equipment. Revision 0.98 was issued 8/28/07, and the production equipment testing was completed on 9/7/07.

The FAT was completed successfully on all of the deliverable equipment.

The test results are documented in the CSI equipment travelers, which contain the complete build configuration and testing history. CSI utilizes travelers to track each ALS board, backplane, chassis/rack, assembly panel, and cable assembly. They contain the associated drawings, schematics, Bill of Material's, material traceability, assembly procedures, configuration information (FPGA loading and setpoints), and test reports. CSI performs a V&V review of the travelers at each stage of manufacturing and test, prior to release for the next stage. Additional details of this system are contained in the Reference 1.1.6 3.5.2.4. Resources The Design Contractor /Class 1E Controls Supplier prepared the FAT procedure, and completed the FAT testing on the deliverable equipment.

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4.

V&V

SUMMARY

The Verification and Validation of the implementation and test phase of the development program for the ALS MSFIS was successfully completed.

Open work items remaining include the following:

Validation Test This System Verification and Validation Report will be updated by revision to reflect the completion of each phase.

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