ML090270826

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Enclosure VII to Wm 09-0001 - CS Innovations Report 6101-00200, Msfis V&V Report, Rev 4
ML090270826
Person / Time
Site: Wolf Creek Wolf Creek Nuclear Operating Corporation icon.png
Issue date: 01/15/2009
From:
CS Innovations
To:
Office of Nuclear Reactor Regulation, Wolf Creek
References
WM 09-0001 6101-00200, Rev 4
Download: ML090270826 (151)
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Enclosure VII to WM 09-0001 CS Innovations Report 6101-00200, "MSFIS V&V Report," Rev 4 Non-proprietary

NON-PROPRIETARY ALS Advanced Logic System 6101-00200 MSFIS V&V Report Revision 4 January 15, 2009 CS Innovations, LLC Scottsdale, AZ

© 2008 CS Innovations, LLC All Rights Reserved

MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC CS Innovations, LLC 9150 E Del Camino, Suite 110 Scottsdale, AZ, 85256 (623) 505-1055 Phone (623) 505-1055 Fax 6101-00200 - MSFIS V&V Report Revision 4 APPROVALS 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 2 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC RECORD OF CHANGES Revision Date Description of changes Made by 0.0 Sept 10, 2007 Compilation of combined V&V Report in ALS format Steen Sorensen 0.2 October 1, 2007 Added a lot of content from FAT Steen Sorensen 1.0 January 31, 2008 General update based on WCNOC Feedback Steen Sorensen Sten Sogaard 2.0 February 22, 2008 Added information from FAT/SAT at WCGS in February Steen Sorensen 2008. Sten Sogaard Modified chapter 2 to reflect the PO change from a non-safety to safety PO.

Updated to reflect review cycle with WCNOC engineers 3 July 28, 2008 Added Proprietary / Non-Proprietary Statements Sten Sogaard 4 January 15, 2009 Added Chapter 11 and 12 Steen Sorensen OPEN ITEMS Description Status Add the Requirement Stage information into the report, CLOSED Migration from Non-safety PO to Safety-related PO CLOSED Include the "re-performing" the inspection / FAT procedure, while WCNOC CLOSED monitors the process and credits it for being the SAT.

6101-00200, Rev 4 CS Innovations, LLC 2009 Page 3 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC Table of Content 1 Intro d u ctio n ...................................................................................................................................................... 10 1.1 P u rp o s e ................................................................................................................................................... 10 1.2 Change from Non-safety to Safety-related P0 (January 2008) ........................................................ 10 1.3 Sum mary Project Description ........................................................................................................... 12 1.4 Sum mary Project Timeline ...................................................................................................................... 13 1.5 V&V Definitions ....................................................................................................................................... 13 1.6 References .............................................................................................................................................. 13 2 V&V Overview .................................................................................................................................................. 14 2.1 Quality Assurance Plan ........................................................................................................................... 14 2.2 Organization ............................................................................................................................................. 15 2.3 CSI V&V Team Responsibility ........................................................................................................... 15 2.4 Tool Identification & Classification .................................................................................................... 16 2.5 Hardware Identification ........................................................................................................................... 17 3 V&V Process ............................................................. ...................................................................................... 18 3 .1 G e n e ra l ................................................................................................................................................... 18 3.2 Verification and Validation Process .................................................................................................. 18 3.3 Life Cycle V&V ........................................................................................................................................ 18 3.4 Verification and Validation Adm inistration ................................................  :............................................. 19 4 Planning (and Requirement) Stage ............................................................................................................ 20 4.1 Stage Sum mary ....................................................................................................................................... 20 4.2 V&V Review of J-105A(Q) - Replacement MSFIS System ............................................................... 22 4.3 6101-00001 - MSFIS Conceptual Design ........................................................................................ 24 4.4 6101-00000 - MSFIS Management Plan ........................................................................................ 25 4.5 6101-00005 - Configuration Management Plan ............................................................................... 26 4.6 6101-00008 - MSFIS V&V Plan ...................................................................................................... 27 4.7 6101-00004 - MSFIS System Test Plan .......................................................................................... 28 4.8 6101-00006 - MSFIS Safety Assessment ......................................................................................... 28 5 Development Stage .......................................................................................................................................... 31 5.1 Stage Sum mary ...................................................................................................................................... 31 5.2 V&V activities during ALS board development ................................................................................. 32 5.9 Review and Pre-Validation of EMI / RFI / Surge ..................................................................................... 53 5.10 Review: Seism ic Test Procedures .......................................................................................................... 55 5.11 Dedication Plan ....................................................................................................................................... 55 5.12 Sum mary: Design Phase V&V Activities .......................................................................... 56 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 4 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 5.13 Com pletion of the Development Stage ............................................................................................. 56 1

6 Manufacturing (and Board Acceptance) Stage ........................................................................................... 57 6.6 V&V Review of NCR's ............................................................................................................................. 66 6.7 V&V Review of ECN's ............................................................................................................................. 66 6.8 Sum m ary of V&V Effort during Manufacturing Stage ........................................................................ 67 7 System Acceptance Test Stage ....................................................................................................................... 68 7.1 Stage Sum m ary ...................................................................................................................................... 68 I 7.6 7.7 7.8 Review the System Configuration .....................................................................................................

V&V Review of NCR's .............................................................................................................................

V&V Review of ECN's .............................................................................................................................

76 77 77 7.9 Sum mary of V&V Effort during Manufacturing Stage ........................................................................ 77 8 FAT/CGD/SAT - Installation (at W CGS) ................................................................................................... 78 CD 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 5 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC CD P

6101-00200, Rev 4 CS Innovations, LLC 2009 Page 6 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC Table of Tables Table 3-1 : V&V Activities ........................................................................................................................................... 19 5r CD Table 6-8: NCR's issued in the Manufacturing Stage ......................................................................................... 66 Table 6-9 : ECN's issued in the Factory Acceptance Test Stage ......................................................................... 66 F(

Table 7-4: NCR's issued in the Factory Acceptance Test Stage ..........................................................................

Table 7-5 : ECN's issued in the Factory Acceptance Test Stage ...........................................................................

77 77 CD 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 7 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC Table of Figures Figure 1-1 Planned Life Cycle, with Nutherm being the safety-related system provider .................................... 11 Figure 1-2: Actual Life Cycle, with CS Innovations being the safety related system provider ............................. 11 F ig u re 1-3 Ide a l Life C yc le ......................................................................................................................................... 12 F ig u re 1-4 : P roject T im e line ....................................................................................................................................... 13 F ig u re 2 -1 : Q A A ctiv itie s ............................................................................................................................................ 14 Figure 2-2 : V&V Oversight of the CSI Design Team ............................................................................................. 15 Figure 5-1: OnTime Defect Tracking .......................................................................................................................... 41 Figure 6-1 Board-level Automated Testing Environment ...................................................................................... 59 C'D 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 8 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC GLOSSARY OF TERMS Term Definition MSFIS Main Steam and Feedwater Isolation Actuation System SRD System Requirements Document HDD Hardware Design Document HRS Hardware Requirements Specification ECN Engineering Change Notice NC(R) Non-Conformance (Report)

CGDP Commercial Grade Dedication Plan CGDR Commercial Grade Dedication Report QAP Quality Assurance Plan V&V Verification and Validation VVP Verification and Validation Plan VVR Verification and Validation Report Term Definition CSI CS Innovations LLC, Scottsdale, Arizona Elite Elite Electronic Engineering INC, Downers Grove, Illinois Nutherm Nutherm International INC, Mount Vernon, Illinois WCNOC / WCGS Wolf Creek Nuclear Operating Corporation INC.

Owner of Wolf Creek Generating Station, Kansas.

Wyle Wyle Test Labs, Huntsville, Al http://www.wylelabs.com/

6101-00200, Rev 4 CS Innovations, LLC 2009 Page 9 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LILC Introduction 1.1 Purpose The Verification & Validation Report (WR) documents the Verification & Validation (V&V) process that was set forth in the Verification & Validation Plan (WP) used in the development of the ALS-based Class 1E safety-related Main Steam and Feedwater Isolation System (MSFIS) developed by CS Innovations (CSI) for Wolf Creek Generating Station (WCGS).

Customer Name Wolf Creek Nuclear Operating Corporation (WCNOC)

Customer P.O. # 734448/0 (Revision 0, initial PO, non safety related) 734448/1 (Revision 1, including NRC modifications) 734448/2 (Revision 2, Internal WCNOC revision) 734448/3 (Revision 3, safety related PO) 734448/4 (Revision 4, safety related PO with updated IP rights)

Internal project ID# D101 The document presents the methodologies and summarizes the results of reviews, tests, and analyses that were deployed to verify and validate the specification, design, implementation, and testing of the MSFIS.

The purpose of the Verification and Validation process is to ensure that the system, including both the hardware and the FPGA related components, meet the performance and reliability requirements set forth in the customer's technical specifications and the governing standards.

The MSFIS V&V Report is planned to be released in 3 steps:

" MSFIS V&V Report, rev 1, following the System/Factory Acceptance Test, Scottsdale, September 2007.

" MSFIS V&V Report, rev 2, following the Factory/Site Acceptance Test, Burlington, February 2008

" MSFIS V&V Report, rev ?, following the Installation o Expected in RF16 (March/April 2008)

The intent of this document is to capture the V&V related activities performed by CSI's independent V&V group. The VVR is a living document, which will be updated periodically throughout the project. The final report will include information regarding all phases of the project and will summarize the entire V&V effort of the CSI independent V&V group.

This VVR reflects the fact that this is a hardware project, which includes the traditional stages of a hardware system. The V&V report has been partitioned in sections following the 'Stages' defined in the V&V plan (each containing multiple phases).

The stages include the Planning stage (section 4), Development stage (section 5), Manufacturing stage (6), System test stage (7), FAT/GCD/SAT-Installation stage (section 8), Operation stage (section 10) - see the project life cycle shown in Figure 1-2.

1.2 Change from Non-safety to Safety-related PO (January 2008)

As indicated in section 1.1 above, the Customer/Supplier relationship initially outlined in the 6101-00000 - MSFIS Management Plan was changed in Q4'07/Q1'08. This change occurred after the equipment had been delivered from CSI to Nutherm and Nutherm had completed FAT & Commercial Grade Dedication tasks.

The consequence of this change in relationship was a change in the PO's scope and responsibilities.

Further, this had consequences to CSI's V&V scope, where an additional step was added to the project life cycle -

see section 1.2.2.

6101-00200, Rev 4 CS Innovations, ILLC 2009 Page 10 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC 1.2.1 The Initial plan (PO 734448/1)

Initially the planned relationship was:

" Equipment supplier: CS Innovations, LLC

" Safety related vendor: Nutherm International, Inc

  • Customer: WCNOC The V&V flow that was initially planned is indicated below Stage Planning Development Manufacturing System Test Installation Phase Concept Planning Requirements Design :Implementation: Test Manufacturing: Test Integration
  • FAT FAT OCGD : SAT  : PIT Project Management Plan j NUTHERM WOLFCREEK

-~o-ns`p-tual 7 I-*_;;1i;*--1_:i Design i:t ______ cetnel cetne~~lai~

Desgn Requiements SpecsD  : Tnutac n Test , ,.......1..Tst Support Board Trvelers Syste Travelers F71::F; 1 Test Design Spesflcution e  : Test Reports Audits and Reviews Audits and Reviews R O Status Accounting, Audits, and Reviews Milestones )4) ) ) ) )4 ) ) )

Figure 1-1 Planned Life Cycle, with Nutherm being the safety-related system provider 1.2.2 The New Plan (734448/4)

Initially the planned relationship was:

  • Equipment supplier: CS Innovations, LLC

" Customer: WCNOC. Where WCNOC has 3 independent V&V teams performing V&V independent of CSI. The three teams being Nutherm International, Baseline Engineering, and WCNOC Engineering.

Stage Planning Development Manufacturing System Test Installation Phase Concept  : Planning  : Requirements Design :Implementation: Test Manufacturing Test Integration FAT FAT/CGD :FAT/CGD/SAT: PIT Project Management Plan UTH ERM U CIWOLF CREEK FCounce-ptu~al-:

Dsg RqimnsI secs) :1 Desig Date TsRpt actunng

_1____

11 uTst on FATF T FAT/I SAT

-II SIu aini

.F_.

Board Travelers System Travelers T; tPlan]* Test Design Specification . n d i

  • ot F and Reviews oAudits G l

-iPo,,.°. an

~~Audits angReviewsR,;

- 1, StatusAccounting, Audits,andReviews _

I~] Revision from non-safety to a safety related PO (73_48/4)

Milestones 4) 4 4) 4 4) 4 4) 4 4) 4) 44 Figure 1-2 Actual Life Cycle, with CS Innovations being the safety related system provider 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 11 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC The project life cycle shown in Figure 1-2 reflects the change occurring in January 2008, where CSI changed from supplying the equipment as commercial grade equipment, to supplying the equipment as a class 1 E safety related product under the CSI Appendix B QA program.

The change included the insertion of an additional phase following the Nutherm FAT/CGD tasks/phase.

The purpose of the additional phase - referred to as FAT/CGD/SAT was threefold:

1) Re-perform the Factory Acceptance Test and re-inspect the board/system to bring the equipment back under control within the CSI Appendix B QA program.
2) Complete the CGD and issue the Certificate of Compliance (C of C).
3) WCNOC I&C technicians monitored and participated in the Test and Inspection activities in order for WCNOC to take credit for the testing performed by CSI as their Site Acceptance Test (SAT).

The FAT/CGD/SAT phase was performed at WCGS in February 2008.

1.2.3 Ideal The ideal ALS board life cycle is shown in Figure 1-3. For references please refer to 6002-00001 ALS QA Plan.

Stage Planning Development Manufacturing System Test Installation 0 Phase Concept Planning Requirements Design :Implementation: Test Manufacturing: Test Integration FAT Dedication SAT PIT Project Management Plan LdsS'ecgs)equire Data Tent . Test Board Traselers System Travelnrs FTtýn TentD..ign Speclisiaton Tes ReTorts I TestReports A PlanAudits andRaese ._

F --- I L Auditsand Reviews Status Aceunting, Audits, and R ienws

it Mistones Figure 1-3 : Ideal Life Cycle 1.3 Summary Project Description The Main Steam and Feedwater Isolation Actuation System (MSFIS) implements two separate, independent and redundant MSFIS subsystems:

" MSFIS Channel I (Separation Group 1) located in MSFIS Cabinet SA075A (train A).

  • MSFIS Channel IV (Separation Group 4) located in MSFIS Cabinet SA075B (train B).

The controls in each channel process a set of contact input signals from other power plant systems and based upon a pre-determined logic the system will control a set of solenoids on 4 Main Steam Isolation Valves (AB-HV-14, AB-HV-17, AB-HV-20, AB-HV-1 1) and 4 main Feedwater Isolation Valves (AE-FV-39, AE-FV-40, AE-FV-41, AE-FV-42).

The controls in each cabinet contain the following components:

  • 2 ALS Racks, one MS-rack and one FW-rack.
  • 1 Assembly panel, with MS and FW components
  • Cables, between vendor and field terminal blocks The Advanced Logic System (ALS) is based on a modular digital hardware platform with input boards, output boards, logic control boards and power supply boards. This system is designed to provide reliable, deterministic operation and the platform utilizes redundant systems, proven hardware techniques, failure detection, fault isolation and fail-safe logic to provide a high integrity solution in a safety critical environment.

The system consists entirely of Commercial off-the-shelf (COTS) equipment. There is no embedded software (firmware) in the system. The unique FPGA image programmed into the FPGA devices located on the boards has been subject to an extensive V&V effort, which is documented in this report.

CS Innovations, LLC 2009 Page 12 of 150 6101-00200, 6101-00200, Rev Rev44 CS Innovations, LLC 2009 Page 12 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC 1.4 Summary Project Timeline The MSFIS project was initiated in April 2004 with conceptual discussions, requirement identification and architectural discussions. The project is expected to complete with installation at WCGS in spring 2008 during refueling outage 16.

NON-SAFETY PO. SAFETY P.O.

/NON-SAFETY P.O. NON-SAFETY P.O.

200 2006 > 2 -0Planned I InsstallDate 1 I Q2 I Q3 I Q4 01 Q I Q2 I Q3 I Q4 01 Q I Q2 I Q3 I 04 01 02 I I I S

  • I$

F SSF TEST IPrototy FATT PCBIHW PCB Design & Builds NEW ALS FAT Complete ALS VHDL VHDLM VHDL uction Build Prototype LS I ALS / MSFIS Conceptual and Architecture Design Establish App B QA Program App. B Program CS Innovations QA Program Update QA App. B Program CA Manual rev 1 \*_ NutFe Nuthen ^ urvery u i QA Manual rev 3 VNutherm Survey Nutheerm Survey Nutherm Survey Wolf Creek Audit TEST EQUIPMENT LI ATU-101 ATS-101 ATU-102 ATS-102 Figure 1-4: Project Timeline 1.5 V&V Definitions See IEEE Std 1012-1998 Annex G, Annex I.

1.6 References Following is a list of references used throughout this document.

Ref Description 1 Specification J-105A(Q) for Replacement MSFIS System, WCGS, Rev 3 2 6101-00008 - MSFIS V&V Plan, CS Innovations, CS Innovations 3 6101-00005 - Configuration Management Plan, CS Innovations 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 13 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC 2 V&V Overview 2.1 Quality Assurance Plan Products provided under PO 734448/4 are being provided under the CS Innovations QA manual, rev 1, dated 5/16/2007, which complies with the applicable requirements of 10 CFR 50 Appendix B.

Defects are reportable according to the requirements of 10 CFR Part 21.

WCNOC has reviewed and approved the CSI 10CFR50 Appendix B QA program and has added CSI to the WCNOC approved suppliers list.

The Quality Assurance Plan (6101-00009 - MSFIS Quality Assurance Plan) was developed in accordance with the requirements of the Quality control Procedure (QCP 3).

2.1.1 Verification and Validation Plan A detailed Verification and Validation Plan (6101-00008 - MSFIS V&V Plan, CS Innovations) was developed for the project and was approved by WCNOC.

The V&V Plan defines the quality assurance steps that shall be invoked in each phase of the development program.

Specific requirements are imposed on the independent Verification and Validation team, which functions independently of the Design and Manufacturing team.

Several specific documents were developed in the process to govern the element of the Quality Assurance process that applied specifically to the FPGA devices.

Hardware Verification and Validation activities were governed by hardware specific documents that were prepared to govern the elements of the Quality Assurance process that applied specifically to the hardware.

Verification and Validation activities were applied essentially equally to both software and hardware aspects of the system development.

2.1.2 Configuration Management Plan A detailed configuration management plan (6101-00005 - Configuration Management Plan, CS Innovations) was developed for the project and was approved by WCNOC.

2.1.3 Relationship between QA related plans The V&V process described in this document is only one of several QA activities. Figure 2-1 shows 3 independent but related activities to all part of the overall quality assurance processes.

Quality Assurance Figure 2-1 : QA Activities 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 14 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC 2.2 Organization The organization of the V&V oversight of the CSI design team is illustrated in Figure 2-2.

Figure 2-2: V&V Oversight of the CSI Design Team WCNOC V&V WCNOC provide independent V&V of the CSI Design team. Independence include:

  • Technical Independence
  • Managerial Independence
  • Financial Independence Nutherm V&V Nutherm provide independent V&V of the CSI Design team. Independence include:
  • Technical Independence
  • Managerial Independence
  • Financial Independence Nutherm provides direct oversight and provides a second level of independent V&V in addition to CSI's internal V&V team. Further, Nutherm provides a set of independent dedication (which now serves as V&V) and qualification plans.

CSI V&V CSI's V&V team provide a technical Independent V&V team. The team is not financially and managerial independent, as the V&V manager also is the President of CSI.

The team consists of Steen Sorensen (V&V Manager), Thomas Christensen, and Paul Blaschka.

The Development activities and tests are verified and validated by the V&V group with significant technical competency.

CSI Design CSI's design team provides it own V&V functions, but no independence can be claimed.

The level of V&V performed by the design team is limited to one designer performing code review, performing test support for another, and reviewer documents for other designers.

2.3 CSI V&V Team Responsibility The CSI V&V team should cover all V&V activities to be performed during all phases of the life cycle.

The V&V Plan (6101-00008 - MSFIS V&V Plan) outlines the details of the work to be performed.

In summary the work includes:

" Analyzing system requirements to determine if they are consistent with, and within the scope of the system.

" Assuring that the requirements are testable and capable of being satisfied.

" Development, of test beds and test vectors.

" Prepare Acceptance Test Plans and verification matrixes, including test specifications and unit test plans.

" Conducting informal reviews and walkthroughs and inspections of the designs.

" Conducting Code inspections and/or walkthroughs.

6101-00200, Rev 4 CS Innovations, LLC 2009 Page 15 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC U

Conducting Unit testing software and data structures.

U Development of detailed test procedures for the next two phases.

Conducting tests per test procedures.

Documenting test performance, test completion, and conformance of test results versus expected results.

U Providing a test report that includes a summary of non-conformances found during testing.

Locating, recording, correcting, and retesting non-conformances.

U By test, analysis, and inspection, demonstrating that the developed system meets its functional, performance, and interface requirements.

2.4 Tool Identification & Classification Tools used throughout the project life cycle are documented in: '6000-00010 - ALS Design Tools'.

All tools are all classified as non-safety related.

The tool suite used for test and V&V includes:

" Automated testing environments:

P CD

" Capture and replay:

L " System monitor:

L " Sequence checker:

" Syntax and data checker:

6101-00200, Rev 4 CS Innovations, LLC 2009 Page 16 of 150

IVISFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 2.5 Hardware Identification 2.5.1 Items on System level - ALS Racks, Panels and Cables

@IxN >

WC-MSFIS System, SA075A (5101-200):

WC-MSFIS, MS ALS Rack 5101-100 WC-MSFIS, MF ALS Rack 5101-101 Assembly Panel, SA075A 4101-036 WC-MSFIS Cable, C1M1 4101-020 WC-MSFIS Cable, C1F1 4101-020 WC-MSFIS Cable, C1M2 4101-024 WC-MSFIS Cable, C1F2 4101-024 WC-MSFIS Cable, C1M3 4101-028 WC-MSFIS Cable, C1F3 4101-028 WC-MSFIS Cable, C1 M4 4101-032 WC-MSFIS Cable, C1 F4 4101-032 WC-MSFIS System, SA075B (5101-201):

WC-MSFIS, MS ALS Rack 5101-100 WC-MSFIS, MF ALS Rack 5101-101 Assembly Panel, SA075B 4101-038 WC-MSFIS Cable, C4M1 4101-022 WC-MSFIS Cable, C4F1 4101-022 WC-MSFIS Cable, C4M2 4101-026 WC-MSFIS Cable, C4F2 4101-026 WC-MSFIS Cable, C4M3 4101-030 WC-MSFIS Cable, C4F3 4101-030 WC-MSFIS Cable, C4M4 4101-034 WC-MSFIS Cable, C4F4 4101-034 2.5.2 Items on Rack level - ALS boards WC-MSFIS, MS/MF ALS Rack ALS-101, ALS Board, Core Logic Board 5101-007 ALS-201, ALS Board, Service & Test Board 5101-008 ALS-301-1, ALS Board, Input Board 5101-010 ALS-301-2, ALS Board, Input Board 5101-011 ALS-401-1, ALS Board, Output Board 5101-012 ALS-411-1, ALS Board, Output Board 5101-001 ALS-411-2, ALS Board, Output Board 5101-002 ALS-411-3, ALS Board, Output Board 5101-003 ALS-905, ALS Board, Power Supply Unit 5101-009 cs Innovations, LLC 2009 Page 17 of 150 6101-00200, Rev4 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 17 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC 3 V&V Process 3.1 General This report documents the V&V steps performed on the ALS-based MSFIS system and describes the V&V process as it was applied to the design process; including the hardware/system design, the manufacturing stage (ALS board testing including FPGA validation), and the implementation and acceptance testing of the complete MSFIS system.

3.2 Verification and Validation Process The Verification and Validation Plan (6101-00008 - MSFIS V&V Plan) was not initially developed to conform to the requirements of IEEE 1012-1998, since the standard is software specific, and does not require imposing requirements on the hardware. Due to the lack of better standards, the principles of a combination of IEEE 1012, IEEE 7-4.3.2 - 2003, and the DO-254 have been applied to both the hardware and the FPGA development. Thus, the V&V plan was applied to define the procedures and requirements for comprehensively evaluating the integrated system, as well as the developed FPGA/ALS boards, through each phase of the life cycle of the Main Steam and Feedwater Isolation Actuation System replacement project.

The V&V process provides the means to ensure that the entire system, including the developed FPGA image, meet the established functional, performance and interface requirements, and that the development process was performed in a manner to ensure predictable results and interface between each phase of the development cycle.

The specific areas addressed by the V&V plan are to ensure:

a. That the system/board/FPGA developers and WCNOC have a mutual understanding of the system requirements.
b. That the development process is devised to eliminate design errors.
c. That the testing requirements demonstrate the quality of the hardware, especially the FPGA images.
d. That the integrated system, hardware and FPGA devices, together complies with all applicable specifications.

3.3 Life Cycle V&V This section provides an overview of the V&V activities that were performed during each phase of the development process for the Main Steam and Feedwater Isolation Valve Actuation System.

Each of the following sections are dedicated to each stage of the development process - see Table 3-1.

The stages and phases used in the project life cycle have been shown/compared with IEEE 12207 and IEEE 1074 phases. Both IEEE standards focus on software projects, and are therefore not really applicable to a hardware project, such as the ALS-based MSFIS project.

The design process generally followed the "Waterfall" model of IEEE 1012 and IEEE 7-4.3.2, however, portions of the design and implementation phases overlapped somewhat, as will be noted in the detailed descriptions to follow.

Especially the hardware (board/PCB) development is done in multiple revisions which is traditional in board development.

The actual process used in a real'-world problem is iterative in its nature. It was therefore decided to document the V&V effort in stages (as opposed to phases) - This offers a more complete picture of the effort on a configuration item in one place.

The V&V plan was performed in parallel to these stages and each stage was designated complete only after its output was verified to comply with the stage's requirements 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 18 of 150

MVSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC CSI (this project)

IEEE 1074 IEEE 12207 Life Cycle Life Cycle Activity Period Done Life Cycle Process Development Process Activities Phases Stages Project Management Process Conceptual design Q2'2004 - Q1'2005 I Management Process Implementation Planning Planning Design planning Q4'2004 - Q2'2005 /

Concept (section 4)

Exploration System Requirement Analysis Requirements Requirements Q1'2005 - Q2'2006 "

System Allocation System Architecture Design Specification Q2'2005 - Q4'2006 I Requirements Software Requirement Analysis Design (HW design and Design Dsg and n analysis nlss Q2'2004 020 7 Q4'2006 420 Software Architecture Design FPGA design) Development Implementation Jan'2006 - Apr'2006 I Design Software detailed Design (section 5) Prototyping Apr'2006 - Aug'2006 ,

Software coding and testing Implementation Tests Aug'2006 - May'2007 /

Test (including EQ Test Aug'2006 - Feb'2007 Implementation EQ test)

Manufacturing Manufacturing of Manufacturing boards, cables, panels Software integration Acceptance Test May2007 - Aug'2007 Software Qualification Testing As System integration Integration System Test Integration Q3'2007 System Qualification Testing FAT (section 7) FAT /

Software Installation FAT /

Installation FAT/GCD/SAT Installation Dedication / C of C Feb'2008 (section 8) Site Acceptance Test Installation Installation Test April'2008 - TBD OperationalQ208-TB Operation Operation Surveillance Q2'2008 - TBD Maintenance (section n/a) Periodic Testing Q2'2008 - TBD Table 3-1 : V&V Activities 3.4 Verification and Validation Administration 3.4.1 Anomaly Reporting and Resolution Any changes determined to be required after initial "Baselining" of affected elements of the design during any phase of the life cycle were implemented through the issue of an Engineering Change Notice (ECN). A task iteration policy was followed if the resolution of such anomalies required a design change or had an impact on design elements completed during a previous phase of the life cycle.

3.4.2 Task Iteration Policy Task iteration was triggered by a customer request, a reported problem, or by a non conformance report. The cause and corrective action were documented by an ECN. Based on the ECN, either a document change, a FPGA change, a hardware change, or an appropriate combination of the three was made. The ECN included identification of consequent changes required to other earlier prepared documents, or if any tests or repeat of previously performed tests needed to be performed. If the item was changed, the corresponding documentation was updated and a test was performed on the affected part. The documentation went through the same thorough review and reconciliation process.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 4 Planning_(and Requirement) Stage 4.1 Stage Summary The following provides details of the V&V activities conducted during the Planning and Requirement stage of the project.

4.1.1 Stage Activities The V&V team shall be responsible for the following V&V tasks during the Concept, Planning and Requirement phases:

1) Review the following documents:
a. J-105A(Q)- Replacement MSFIS System (Customer Requirement Specification)
b. 6101-00001 - MSFIS Level-0 Specification (Conceptual design)
i. Conceptual design document satisfies customer needs and is consistent with the PO.

Validate constraints of interfacing systems and constraints or limitations of proposed approaches. Analyze concept documents to validate that the following satisfy customer needs: System functionality, end-to-end system performance, operation and maintenance requirements, test requirements, environmental qualification requirements, etc.

c. 6101-00000- MSFIS Management Plan
2) Generation of the following documents:
a. 6101-00008 - MSFIS V&V Plan
b. 6101-00004 - MSFIS System Test Plan
c. 6101-00005 - Configuration Management Plan (CMP).
d. 6101-00006 - MSFIS Safety Assessment
e. 6000-00008 - ALS Board Test Plan
3) Conceptual explorations of critical issues
a. Solid State output driver circuits 4.1.2 Stage V&V activities The V&V activities are twofold, i.e. generating a set of documents, and reviewing a set of documents.

The review methods employed in the V&V effort consists of dedicated and focused document reviews, where documents are reviewed and validated for the following characteristics:

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC Consistency Completeness L

  • Verify the Specification satisfy specified configuration management procedures.

Accuracy SReadability Testability 2 Verify that there are objective acceptance criteria for validating the requirements of the Specification The V&V reviews performed in these phases require highly experience engineers with in-depth knowledge of the systems, the methods, the implementations and the processes.

4.1.3 Stage Acceptance The Criteria of Acceptance for a successful V&V effort during the planning stage is a set of approved documents -

see section 4.1.1.

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IVISFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.2 V&V Review of J-105A(Q) - Replacement MSFIS System 4.2.1 Purpose Review customer specification for completeness and consistency. Because of the novelty of the ALS bases MSFIS system there was naturally many issues in the customer's specifications which had to be revised. An example of such issue was that the original specification required relays to be used.

Such inconsistencies between the customer specification and CS Innovations' conceptual design document and requirements specification was fed back to WCNOC and incorporated in later revisions.

4.2.2 When WCNOC made official releases of the J-1 05A(Q) specification throughout the project:

J-105A(Q) Revision 0 - Approved and released 09/14/2005 J-105A(Q) Revision 1 - Approved and released 04/04/2006 J-105A(Q) Revision 2 - Approved and released 08/08/2006 J-105A(Q) Revision 3 - Approved and released 06/29/2007 4.2.3 V&V Effort Review all requirements in customer specification. Ensure all requirements were clearly and precisely described and was defined such that their achievement was capable of being objectively verified and validated.

Feedback to WCNOC of the J-105A(Q) specification in 2 ways; (a) Informal reviews where editorial issues as we well as overall clarifications were conveyed to WCNOC (b) Written on formal WCNOC 'Document Comment Sheets' 4.2.4 Findings 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 22 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.2.5 Result All findings identified by V&V activities were incorporated in the latest Customer Specification from WCNOC.

The specification was found to be acceptable.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.3 6101-00001 - MSFIS Conceptual Design 4.3.1 Purpose Conceptual design document satisfies customer needs and is consistent with the PO.

Validate constraints of interfacing systems and constraints or limitations of proposed approaches. Analyze concept documents to validate that the following satisfy customer needs: System functionality, end-to-end system performance, operation and maintenance requirements, test requirements, environmental qualification requirements, etc.

4.3.2 When PCD 4.3.3 V&V Effort The V&V effort was mainly focused on review to ensure the technical aspects of the document were adequate, as well as the documentation meet the criteria's set forth in section 4.1.2.

4.3.4 Findings and Results All findings identified by V&V were immediately incorporated into the next revision of the un-released document.

The document (MSFIS_ConceptualDesignDocument_vl_0) was successful released to WCNOC.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.4 6101-00000- MSFIS Management Plan 4.4.1 Purpose The purpose of the V&V effort was the review of the Management Plan.

P CD 4.4.3 V&V Effort The V&V efforts related to the MSFIS Management plan was to review and provide feedback.

4.4.4 Findings and Result The MSFIS Management plan (6101-00000 - MSFIS Management Plan) implemented by CSI was adequate and acceptable.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.5 6101-00005- Configuration Management Plan 4.5.1 Purpose This CM Plan was initially implemented by Spectrum Technologies (3 rd party independent V&V engineering team involved in the initial phases of the project). Spectrum Technologies had been involved with the development of the MSFIS based system utilizing Allen Bradley PLC's at the Callaway Nuclear plant.

Later the scope changed, and CSI initiated the generation of a CM plan independent of the 3rd party 10CFRS0 Appendix B partners. This plan obsoletes the previous plans generated by Spectrum Technologies.

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4.5.3 V&V Effort The CM effort changed from being the reviewer of the CM plan (WCGS MSFIS Configuration Management Plan) to actual generation of the plan (6101-00005- Configuration Management Plan).

4.5.4 Findings and Result The CM plan implemented by Spectrum Technologies was acceptable, but proved to be insufficient.

The CM plan (6101-00005 - Configuration Management Plan) implemented by CSI was adequate and acceptable.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.6 6101-00008 - MSFIS V&V Plan 4.6.1 Purpose This V&V Plan was initially implemented by Spectrum Technologies (3 d party independent V&V engineering team involved in the initial phases of the project). Spectrum Technologies had been involved with the development of the MSFIS based system utilizing Allen Bradley PLC's at the Callaway Nuclear plant.

Later the scope changed, and CSI initiated the generation of a V&V plan independent of the 3rd party 10CFR50 Appendix B partners. This plan obsoletes the previous plans generated by Spectrum Technologies.

C.P CD 4.6.3 V&V Effort The V&V effort changed from being the reviewer of the V&V plan (WCGS MSFIS System Verification and Validation Plan) to actual generation of the plan (6101-00008 MSFIS V&V Plan).

4.6.4 Findings and Result The V&V plan implemented by Spectrum Technologies was acceptable, but proved to be insufficient.

The V&V plan (6101-00008 - MSFIS V&V Plan) implemented by CSI was adequate and acceptable.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.7 6101-00004 - MSFIS System Test Plan 4.7.1 Purpose The V&V team was responsible for generation of the "6101-00004 - MSFIS System Test Plan" document.

CD CD 4.7.4 Findings All findings identified by V&V, Nutherm and WCNOC were immediately incorporated into the next revision of the un-released document.

4.7.5 Result 6101-00004 - MSFIS System Test Plan, Revision 0 was released, and used to validate the system function on the system which was sent to Nutherm for qualification.

6101-00004 - MSFIS System Test Plan, Revision 0.98 was released, and used during the FAT (MSFIS System Acceptance Test) performed in Scottsdale in Sept'2007 (see chapter 7).

6101-00004 - MSFIS System Test Plan, Revision I was released, and used during the FAT/CGD/SAT phase performed at WCGS in Feb'2008 (see chapter 8 - specifically section 8.3.5.2).

4.8 6101-00006- MSFIS Safety Assessment This document was not initially planned to be generated by CSI, but instead was implemented by WCNOC's independent V&V engineer (Baseline Engineering) - the document is referred to as 'System Reliability Analysis for Advanced Logic System'.

Note: CSI release an independent safety assessment: '6101-00006 MSFIS Safety Assessment' in June 2007 (when a request was made by NRC).

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 4.9 6000-00008 - ALS Board Test Plan 4.9.1 Purpose The V&V team was responsible for generation of the "6000-00008 - ALS Board Test Plan" document.

4.9.2 When P

C'D The '6000-00014 -ALS Board Test Plan' document was released on the following dates:

Revision Date Description of changes 0.01 Feb 1,2008 Release 4.9.3 V&V Effort The V&V effort was mainly focused on generating the document, specifying the test system, specifying the test specifications, specifying the test cases and specifying the test procedures to test the ALS boards.

WCNOC provided independent review of the document. All document feedback was provided within document comments, which were then discussed on conference calls. WCNOC had less influence on the document due to the very technical nature of the implementation.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 5 Development Stage____

5.1 Stage Summary The following provides details of the V&V activities conducted during the design phase, implementation phase and test phase of the development stage.

5.1.1 Stage Activities The Development stage consists of a:

1) Design Phase: where requirements are refined and the items are designed
2) Implementation Phase: where items are implemented
3) Test Phase: where items are tested and qualified.

Following a successful development stage the items can be baselined, and are then ready for production.

The items which are designed, implemented and tested in the development stage include:

5.1.2 Stage V&V activities A number of iterations affecting the outputs of previous phases were performed, affecting both the Conceptual Design and Requirements Phases. The specific iterations performed are detailed in the following description of the V&V activities performed during the Design Phase.

The methods employed in the V&V of the Design Phase consisted principally of visual review of documents and drawings against the preceding phase outputs, 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 customer's specification and work properly after installation irrespective of the specification requirements.

The V&V tasks of the design phase of the development process for the MSFIS consisted of several activities as follows:

" Design Document Review:

o Review the J105A(Q) Customer Requirements Specification delivered by WCNOC

" Review and approval of Hardware Design Documents prepared by the design team

" On a continued basis verify the design, as well as the used design processes are in-line with the appropriate procedures. Conducting informal reviews, walkthroughs and inspections of the preliminary designs and associated data-base.

" Prepare the following documents:

o 6000-00008 - "ALS Board Test Plan" and verify its in-line with the design.

o 6101-00004 - "MSFIS System Test Plan" and verify its in-line with the design.

o 6101-00006 - "MSFIS Safety Assessment" and verify its in-line with the design.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 5.2 V&V activities during ALS board development 5.2.1 Purpose Review all internally generated design specification. The design specifications were reviewed to ensure it presented a structured description of the design and addressed all requirements presented in the customer specification.

Review and provide oversight of the design and implementation of the ALS boards. The V&V activities was introduces at the very beginning of the board developments and followed the boards from prototypes to final release.

The design specifications was reviewed and revised on a continuously basis with many informal meetings and reviews. The finals design specification was reviewed as a part of the either:

CD The design specifications reviewed by V&V are:

P CD 5.2.2 ALS board development time-line The table below shows all ALS boards created as a part of the WC MSFIS project. In this context board development refer to engineering efforts associated with making electronic assemblies based on printed circuit board assemblies. For each item the design completion date and status has been listed.

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IVISFIS V&V Report Non-Proprietary CS Innovations LLC 5.2.3 V&V Effort The V&V efforts included:

  • Review of pre-release versions of schematics, Gerber artwork and BOMs, performed as informal reviews.
  • Review of final release versions of schematics, Gerber artwork and BOMs.
  • Review board design packet following CS Innovations Review Procedure (Reference 9002-00025 - "Board Design Review Procedure").

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC CD 5.2.5 Result The conclusion of the V&V activities which took place during the development of the ALS board is that all issues and finding identified by V&V have been resolved to the satisfaction of the V&V team. The findings which had been identified on older revisions were corrected and reviewed on later revisions. The issues found during the engineering versions of the board developments were viewed upon as being a normal and expected part of engineering development efforts.

The V&V team found all engineering changes was clearly identified and documented.

All final releases of the ALS boards were reviewed by V&V and found to be acceptable based on the above discussion, and no issues remained open at the exit of the development phase.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 5.3 VHDL Rapid Prototype Implementation 5.3.1 Purpose The design team and V&V team made a rapid VHDL implementation in order to implement a prototype FPGA image. Prototyping was used as an integrated part of the system design process, in order to reduce the overall project risk. Prototyping was used to quickly putting together a working model in order to test various aspects of a design, illustrate ideas and new features and gather early customer feedback from WCNOC.

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IVISFIS V&V Report Non-Proprietary CS Innovations LLC 5.5 V&V activities during FPGA development activities 5.5.1 Purpose To review and provide oversight over the implementation and testing of the FPGA images used on the FPGA based ALS boards.

The V&V team consisted of team members from the original fast prototype design team, who based on the experience gained from the prototype build had gained significant insight in the functionality and requirements of MSFIS. (Reference section 5.3).

Although the functionality of the functionality of the prototype was near identical to the functionality of the final system, none of the original VHDL code base was maintained between the prototype and the final design effort.

Only the physical FPGA's, the board, and the implementation tools were transferred over the final design.

The engineering team members chosen for the detailed design and implementation of the FPGA binaries was experienced FPGA/ASIC design engineers with a proven track record in design, implementation and test of digital circuits.

5.5.2 When The V&V efforts performed on the design activities related to the FPGA image was ongoing throughout the design, implementation and testing. To provide a better overview over these activities this section has been split up into 2 section describing activities taking place prior to release and the actives taking place as a part of the release.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC CD 5.5.5 Result The final result of the FPGA review was an approval signoff of the FPGA revision 1.00 for FPGA Image P/N:

ALS-101 FPGA Image P/N 1200-00000 ALS-201 FPGA Image P/N 1200-00001 ALS-301 FPGA Image P/N 1200-00002 ALS-401 FPGA Image P/N 1200-00003 ALS-411 FPGA Image P/N 1200-00004 7C 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 47 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 5.6 Prepare V&V related Documents The V&V team was responsible for the creation of the 3 following documents.

1) 6000-00008 - "ALS Board Test Plan"
2) 6101-00004 - "MSFIS System Test Plan"
3) 6101-00006 - "MSFIS Safety Assessment" 5.6.1 ALS Board Test Plan The ALS board Test Plan (ATP) provides a detailed description of the Test Plan and Procedures used to test Advanced Logic System (ALS) Boards. The document includes the following:
  • Test Plan - A comprehensive plan to conduct V&V and acceptance testing of ALS boards.

" Requirement Traceability Matrix - Describes the relationship between the test requirements and the associated test cases (test vectors) and test procedures which support V&V of the ALS boards.

  • Test Procedures o Description of the verification and simulation test environments which are used for testing.

o Release test procedure used when releasing a new board revision.

o Description of an acceptance test plan used for test of board during manufacturing.

The Test Plan with all the described Test Procedures are used to formally sign-off the ALS Board for baselining, as well as the final validation and acceptance testing following the board manufacturing phase.

The ALS Board Test Plan was a developed by the V&V team with review support from engineering.

5.6.2 MSFIS System Test Plan The MSFIS System Test Plan contains a detailed plan for verification and validation of the Main Steam and Feedwater Isolation System (MSFIS).

The MSFIS test plan is created by V&V based on the requirements described in:

  • J-105A(Q) - Specification for Replacement MSFIS System
  • 6101-00002 - MSFIS System Specification A Requirement Traceability Matrix describes the relationship between a set of test requirements, the associated test vectors which support the V&V process.

The MSFIS Test Plan was a developed by the V&V team with review support from engineering.

The MSFIS Test Plan describes a test suite used for:

  • System-level Automated Testing utilized the Automatic Test Equipment (ATE) developed by CS Innovations (see section 7.2.2). The ATE consists of an ATU-101 which is a dedicated hardware test system and the ATS-101 software suite which runs the golden test vector (GTV).
  • System-level Manual Test Environment where the MSFIS system can be tested using an operator panel to provide inputs (OPEN, CLOSE, ESFAS, etc) and a load bank for creating a realistic load scenario.

The Test Plan with all the described Test Procedures are used to formally sign-off the MSFIS system.

5.6.3 MSFIS Safety Assessment The.MSFIS safety assessment is performed to locate, identify, and assess the impact of a failure in the WCNOC MSFIS based on the Advanced Logic System (ALS). It includes a preliminary system safety assessment which identifies critical paths in MSFIS.

The Safety Assessment is used in the 6101-00002 - MSFIS System Specification, where it was used to guide the implementation of the ALS bases MSFIS.

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IMSFIS V&V Report Non-Proprietary CS Innovations ILLC MSFIS V&V Report Non-Proprietary CS Innovations LLC The Safety Assessment includes:

  • A system level FMEA analysis of the major components in the MSFIS system.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 5.7 Automated Test Equipment 5.7.1 Purpose The V&V team decided that the ability to perform automatic testing on the individual ALS board and on the MSFIS system was a priority. The automatic testing was not viewed upon as a replacement for automatic testing, but rather as the means to generate an extensive regression test suite which to be easily repeated during development and later for during manufacturing. Having an automated regression test suite enabled the CS Innovations in performing very extensive acceptance tests on all ALS board and the MSFIS system.

As a consequence the V&V team defined a set of requirements to an ATE. The ATE was defined a dedicated tool designed specifically for testing individual ALS boards as well as testing completed ALS Systems such as the

_MSFIS system.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 5.9 Review and Pre-Validation of EMI / RFI / Surge 5.9.1 Acceptance Criteria Meet the guidelines of:

" NUREG 1.180 revl

" EPRI TR-102323 rev 1 - 1997

" EPRI TR-102323 rev 2 - 2000

" EPRI TR-102323 rev 3 - 2004 P

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5.10 Review: Seismic Test Procedures The V&V effort related to Seismic Qualification was on a review and comment basis.

5.10.1 CSI Seismic V&V effort The V&V group performed multiple investigations into the durability, reliability and structural strength of the rack used in the ALS platform.

The rack was found to be acceptable for any class 1E RPS application.

5.10.2 Seismic Test Plan & Procedures Review Due to the arrangement between WCNOC, Nutherm and CSI, then CSI were in a 3rd party reviewer role regarding the Seismic tests. CSI did not have approval rights to the Nutherm controlled test.

ICSI reviewed Nutherm Seismic Test Procedure, S-128P, on each occupation of its release:

CSI did not have any significant feedback on the Seismic tests.

I 5.10.3 Seismic Test Execution Nutherm conducted the seismic test a Wyle Test Labs in January 2007.

WCNOC provided mechanical engineering oversight.

CSI was not present at the test.

The results are documented by Nutherm Qualification Report in the 'WCN-9715R, Rev.0 (February 2007).

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 5.12 Summary: Design Phase V&V Activities 5.12.1 Reviewed &Approved Documents The following documents were prepared by the Design team, and reviewed and approved by the V&V team.

CD o-5.12.2 Prepared Documents The following documents were prepared by the V&V team.

CD 5.13 Completion of the Development Stage The V&V conclusion of the Development Stage was that all development efforts were completed in a satisfactory manner. Engineering prototypes were created of the ALS based MSFIS system and used to provide engineering with proof of design/concept before finalizing the design. V&V reviewed and audited the development team throughout the developments and found that the following items had been performed to the satisfaction of the V&V team:

  • ALS board had been development and tested

" FPGA developments had been developed and tested

  • Test Plan and Test Procedures had been created

" Assembly and traveler documents had been prepared to ensure consistent manufacturing

  • A thorough EQ plan was created

" Qualification Prototype of MSFIS was created and passed EQ EQ Testing was accomplished with an acceptable and satisfactory result, and meets and exceeds:

" Reg. Guide 1.180 rev 1

" EPRI 102323 rev 1

" EPRI 102323 rev 2

" EPRI 102323 rev 3 Most test with a margin greater than 20dB. The design is suitable for commercial plants, nuclear subs, and carrier applications.

EMI test performed by CSI to independently validate EMI performance.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 6Manufacturing (and BoardAcc pane) Stage The V&V effort during the manufacturing stage was twofold:

" V&V Review of Procedures used in Manufacturing

" V&V Review of Traveler's P

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary Cs innovations LLC CD 6.4 Review of Test Equipment The ALS Test Unit (AUT-1 01) as shown below in Figure 6-1 is the main test tool used for automated tests. Each of the ALS Board was tested using the ATU-101. All tests executed within the ATE verification environment support self-checking tests and produce a PASS/FAIL upon completion of the test execution. The test environment provide significant test coverage of each board, which together with the associated manual test procedure provide a complete Board Acceptance Test.

ALS Test Equipment (ATE)

U I

Figure 6-1 Board-level Automated Testing Environment P

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MSFIS V&V Report Non-Proprietary CS Innovations LLC 6.4.2 Review of Test Equipment In particular, the V&V team focused on reviewing the GTV's vectors, which resulted in the final vector suite.

A large numbers of tests were conducted by the V&V group to gain confidence in the GTV's and the test equipment itself, including the ATS-101 software suite and the ATU-101 hardware tester.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 6.6 V&V Review of NCR's Twenty-two NC was generated during the Manufacturing Stage - see Table 6-8. The complete list of NC's generated during the MSFIS project can be seen in Appendix D: NCR's Related to MSFIS.

Non Conformance # State NC101- 0001 Closed NC101- 0002 Closed NC101- 0003 Closed NC101- 0004 Closed NC101- 0005 Closed NC101- 0006 Closed NC101- 0007 Closed NC101- 0008 Closed NC101- 0009 Closed NC101- 0010 Closed NC101- 0011 Closed NC101- 0012 Closed NC101- 0013 Closed NC101- 0014 Closed NC101- 0015 Closed NC101- 0016 Closed NC101- 0017 Closed NC101- 0018 Closed NC101- 0019 Closed NC101- 0020 Closed NC101- 0021 Closed NC101- 0022 Closed Table 6-8 : NCR's issued in the Manufacturing Stage 6.7 V&V Review of ECN's One ECN was generated from the board acceptance test process during the Manufacturing Stage.

Non Conformance # State ECN101-0003 Closed Table 6-9 : ECN's issued in the Factory Acceptance Test Stage CD 6101-00200, Rev 4 CS Innovations, LLC 2009 Page 66 of 150

MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 6.8 Summary of V&V Effort during Manufacturing Stage All Items (see list in section 2.5.2) were tested and validated.

All travelers, procedures, work-instructions and reports were review and approved.

All travelers filled out during manufacturing were review and approved.

All NCR's were review and approved.

All ECN's were review and approved.

The ALS Board Acceptance Testing was executed according to the acceptance test procedure. The validation testing was successful and the device tested met all of the requirements of the ALS Specification.

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MSFIS V&V Report Non-Proprietary CS Innovations LILC MSFIS V&V Report Non-Proprietary CS Innovations LLC Il ,System Acceptance Test Stage _

Important note:

The original plan with the 'WCNOC MSFIS Project' called for Nutherm to be the 10CFR50 Appendix B vendor, and the FAT would therefore be performed by Nutherm, at Mount Vernon, II, using the Nutherm FAT procedure.

However, in order for CSI to insure a quality delivery, an independent system test plan (6101-00004),

was developed. The system test plan tested the delivered equipment to the same degree (or in fact better) than the Nutherm manual FAT procedure would do. The test consisted of both manual and automatic aspects utilizing the ATE equipment.

The Test Plan/Procedure was executed, as if in fact, the equipment was being delivered to WCNOC as 10CFR50 Appendix B safety related equipment.

The only exception to an ordinary 10CFR50 Appendix B delivery was the lack of a C of C issued in the end after the testing.

7.1 Stage Summary In the system test stage the verified hardware components produced in the manufacturing stage is integrated into a completed system, capable of performing the function described in the customer requirements. CSI performs a very exhaustive system tests suite to provide a complete verification that the system meet the customer requirements.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 7.3 V&V Review of Procedures used in MSFIS Acceptance Testing Nutherm FAT procedure, the Technical Procedure TPS-9064, rev 0 was released a series of times in the period from May-July 2006.

The Nutherm FAT procedure was an independent re-compilation of CSI's 6101-00005 - MSFIS System Test Plan.

CSI conducted a complete review of the rev. 0 and provided the feedback to Nutherm with the required changes related to functionality and performance. Feedback reference: "Review - FAT - 2007-05-29.pdf".

7.4 V&V Monitoring and Participation in Test Execution The V&V effort included active participation during the system Acceptance testing to ensure all processes and tools operate as expected.

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MSFIS V&V Report Non-Proprietary CS Innovations LLC MSFIS V&V Report Non-Proprietary CS Innovations LLC 7.6 Review the System Configuration The V&V review included verification of the System configuration of all the MSFIS racks.

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IVISFIS V&V Report Non-Proprietary CS Innovations LILC MSFIS V&V Report Non-Proprietary CS Innovations LLC 7.7 V&V Review of NCR's One NC was generated during the Factory Acceptance Stage - see Table 6-8. The complete list of NC's generated during the MSFIS project can be seen in Appendix D : NCR's Related to MSFIS.

Non Conformance # State NC101- 0023 Closed Table 7-4 : NCR's issued in the Factory Acceptance Test Stage CD 7.8 V&V Review of ECN's One ECN was generated during the Factory Acceptance Test, as a consequence to the non-conformance report NC101-0023 (see section 7.7).

Non Conformance # State ECN101-0004 Closed Table 7-5 : ECN's issued in the Factory Acceptance Test Stage ECN101-0004 was successfully implemented and closed.

The complete list of ECNs can be seen in Appendix E: ECN's Related to MSFIS Project. -

7.9 Summary of V&V Effort during Manufacturing Stage All Items (see list in section 2.5.1) were tested and validated.

All travelers, procedures, work-instructions and reports were review and approved.

All travelers filled out during manufacturing were review and approved.

All NCR's were review and approved.

All ECN's were review and approved.

The MSFIS system Acceptance Testing was executed according to the acceptance test procedure. The validation testing was successful and the device tested met all of the requirements of the MSFIS System Specification as well as the J-105A(Q).

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IVISFIS V&V Report Non-Proprietary CS Innovations LILC MSFIS V&V Report Non-Proprietary CS Innovations LLC FAT/CGD/SAT - Installation (at WCGS)

The goal of the testing and inspection activities was to allow WCNOC receipt inspection to transition the MSFIS system into safety related storage in the WCGS warehouse.

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CD 8.8 Conclusion The FAT/SAT was completed successfully.

Test incidences and nonconformance's were resolved to the satisfaction of V&V.

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