Reactor Protection & Control Process Instrumentation Replacement Project at DC Cook Nuclear Plant Units 1 & 2 Test Program Summary.| ML17329A719 |
| Person / Time |
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| Site: |
Cook  |
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| Issue date: |
12/10/1992 |
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| From: |
AMERICAN ELECTRIC POWER SERVICE CORP. |
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| To: |
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| Shared Package |
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| ML17329A705 |
List: |
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| References |
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| 2985-BJB-01, 2985-BJB-01-R00, 2985-BJB-1, 2985-BJB-1-R, NUDOCS 9212180090 |
| Download: ML17329A719 (7) |
|
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Rev 1 to Containment Sump Level Design Condition & Failure Effects Analysis for Potential Draindown Scenarios.
ML17326A1481999-09-17017 September 1999
Independent Review of Control Rod Insertion Following Cold Leg Lbloca,Dc Cook,Units 1 & 2.
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1999-09-28
[Table view]
Category:TEXT-SAFETY REPORT
MONTHYEARML17335A5641999-10-18018 October 1999
LER 99-024-00:on 990708,literal TS Requirements Were Not Met by Accumlator Valve Surveillance.Caused by Misjudgement Made in Conversion from Initial DC Cook TS to W Std Ts.Submitted License Amend Request.With 991018 Ltr
ML17335A5531999-10-0707 October 1999
LER 99-023-00:on 990907,inadequate TS Surveillance Testing of ESW Pump ESF Response Time Noted.Caused by Inadequate Understanding of Plant Design Basis.Surveillance Tests Will Be Revised & Implemented
ML17335A5631999-09-30030 September 1999
Monthly Operating Rept for Sept 1999 for DC Cook Nuclear Plant,Unit 1.With 991012 Ltr
ML17335A5621999-09-30030 September 1999
Monthly Operating Rept for Sept 1999 for DC Cook Nuclear Plant,Unit 2.With 991012 Ltr
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Non-proprietary DC Cook Nuclear Plant Units 1 & 2 Mods to Containment Sys W SE (Secl 99-076,Rev 3).
ML17335A5451999-09-28028 September 1999
Rev 1 to Containment Sump Level Design Condition & Failure Effects Analysis for Potential Draindown Scenarios.
ML17326A1291999-09-17017 September 1999
LER 99-022-00:on 990609,electrical Bus Degraded Voltage Setpoints Too Low for Safety Related Loads,Was Discovered. Caused by Lack of Understanding of Design of Plant.No Immediate Corrective Actions Necessary
ML17326A1481999-09-17017 September 1999
Independent Review of Control Rod Insertion Following Cold Leg Lbloca,Dc Cook,Units 1 & 2.
ML17326A1211999-08-31031 August 1999
Monthly Operating Rept for Aug 1999 for Cook Nuclear Plant, Unit 2.With 990915 Ltr
ML17326A1201999-08-31031 August 1999
Monthly Operating Rept for Aug 1999 for Cook Nuclear Plant, Unit 1.With 990915 Ltr
ML17326A1121999-08-27027 August 1999
LER 99-021-00:on 990728,determined That GL 96-01 Test Requirements Were Not Met in Surveillance Tests.Caused by Failure to Understand Full Extent of GL Requirements. Surveillance Procedures Will Be Revised or Developed
ML17326A1011999-08-26026 August 1999
LER 99-020-00:on 990727,EDGs Were Declared Inoperable.Caused by Inadequate Protection of Air Intake,Exhaust & Room Ventilation Structures from Tornado Missile Hazards. Implemented Compensatory Measures in Form of ACs
ML17326A0911999-08-16016 August 1999
LER 99-019-00:on 990716,noted Victoreen Containment Hrrms Not Environmentally Qualified to Withstand post-LOCA Conditions.Caused by Inadequate Design Control.Reviewing Options to Support Hrrms Operability in Modes 1-4
ML17326A0771999-08-0404 August 1999
LER 98-029-01:on 980422,noted That Fuel Handling Area Ventilation Sys Was Inoperable.Caused by Original Design Deficiency.Radiological Analysis for Spent Fuel Handling Accidents in Auxiliary Bldg Will Be Redone by 990830
ML17335A5461999-08-0202 August 1999
Rev 0 to Evaluation of Cook Recirculation Sump Level for Reduced Pump Flow Rates.
ML17326A0871999-07-31031 July 1999
Monthly Operating Rept for July 1999 for DC Cook Nuclear Plant,Unit 1.With 990812 Ltr
ML17326A0861999-07-31031 July 1999
Monthly Operating Rept for July 1999 for DC Cook Nuclear Plant,Units 2.With 990812 Ltr
ML17326A0741999-07-29029 July 1999
LER 99-018-00:on 990629,determined That Valve Yokes May Yield Under Combined Stress of Seismic Event & Static,Valve Closed,Stem Thrust.Caused by Inadequate Design of Associated Movs.Operability Determinations Were Performed for Valves
ML17326A0661999-07-26026 July 1999
LER 99-017-00:on 990625,noted That Improperly Installed Fuel Oil Return Relief Valve Rendered EDG Inoperable.Caused by Personnel Error.Fuel Oil Return Valve Was Replaced with Valve in Correct Orientation.With 990722 Ltr
ML17326A0651999-07-22022 July 1999
LER 98-014-03:on 980310,noted That Response to high-high Containment Pressure Procedure Was Not Consistent with Analysis of Record.Caused by Inadequate Interface with W. FRZ-1 Will Be Revised to Be Consistent with New Analysis
ML17326A0491999-07-13013 July 1999
LER 99-016-00:on 990615,TS Requirements for Source Range Neutron Flux Monitors Not Met.Caused by Failure to Understand Design Basis of Plant.Procedures Revised.With 990713 Ltr
ML17326A0331999-07-0101 July 1999
LER 99-004-01:on 971030,failure to Perform TS Surveillance Analyses of Reactor Coolant Chemistry with Fuel Removed Was Noted.Caused by Ineffective Mgt of Tss.Chemistry Personnel Have Been Instructed on Requirement to Follow TS as Written
ML17326A0511999-06-30030 June 1999
Monthly Operating Rept for June 1999 for DC Cook Nuclear Plant,Unit 2.With 990709 Ltr
ML17326A0501999-06-30030 June 1999
Monthly Operating Rept for June 1999 for DC Cook Nuclear Plant,Unit 1.With 990709 Ltr
ML17326A0151999-06-18018 June 1999
LER 99-014-00:on 990521,determined That Boron Injection Tank Manway Bolts Were Not Included in ISI Program,Creating Missed Exam for Previous ISI Interval.Caused by Programmatic Weakness.Isi Program & Associated ISI Database Modified
ML17325B6421999-06-0101 June 1999
LER 99-013-00:on 990327,safety Injection & Centrifugal Charging Throttle Valve Cavitation During LOCA Could Have Led to ECCS Pump Failure.Caused by Inadequate Original Design Application of Si.Throttle Valves Will Be Developed
ML17325B6311999-06-0101 June 1999
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ML17326A0061999-05-31031 May 1999
Monthly Operating Rept for May 1999 for Dcp.With 990609 Ltr
ML17326A0071999-05-31031 May 1999
Monthly Operating Rept for May 1999 for DC Cook Nuclear Plant,Unit 2.With 990609 Ltr
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LER 99-S02-00:on 990428,vulnerability in Safeguard Sys That Could Allow Unauthorized Access to Protected Area Was Noted. Caused by Inadequate Original Plant Design.Mods Were Made to Wall Opening to Eliminate Nonconforming Conditions
ML17265A8231999-05-24024 May 1999
LER 98-037-01:on 990422,determined That Ice Condenser Bypass Leakage Exceeds Design Basis Limit.Caused by Pressure Seal Required by Revised W Design Not Incorporated Into Aep Design.Numerous Matl Condition Walkdowns & Assessments Made
ML17325B6001999-05-20020 May 1999
LER 99-012-00:on 990420,concluded That Auxiliary Bldg ESF Ventilation Sys Not Capable of Maintaining ESF Room Temps post-accident.Caused by Inadequate Control of Sys Design Inputs.Comprehensive Action Plan Being Developed
ML17325B5861999-05-10010 May 1999
LER 99-002-00:on 990415,discovered That TS 4.0.5 Requirements Were Not Met Due to Improperly Performed Test. Caused by Incorrect Interpretation of ASME Code.App J Testing Will Be Completed & Procedures Will Be Revised
ML17325B5811999-05-0404 May 1999
LER 99-011-00:on 990407,air Sys for EDG Will Not Support Long Operability.Caused by Original Design Error.Temporary Mod to Supply Makeup Air Capability in Modes 5 & 6 Was Prepared
ML17325B5771999-05-0303 May 1999
LER 99-010-00:on 990401,RCS Leak Detection Sys Sensitivity Not in Accordance with Design Requirements Occurred.Caused by Inadequate Original Design of Containment Sump Level. Evaluation Will Be Performed to Clearly Define Design
ML17335A5301999-04-30030 April 1999
Monthly Operating Rept for Apr 1999 for DC Cook Nuclear Plant,Unit 1.With 990508 Ltr
ML17335A5291999-04-30030 April 1999
Monthly Operating Rept for Apr 1999 for DC Cook Nuclear Plant,Unit 2.With 990508 Ltr
ML17325B5581999-04-16016 April 1999
LER 99-006-00:on 990115,personnel Identified Discrepancy Between TS 3.9.7 Impact Energy Limit & Procedure 12 Ohp 4030.STP.046.Caused by Lack of Design Basis Control.Placed Procedure 12 Ohp 4030.STP.046 on Administrative Hold
ML17325B5471999-04-12012 April 1999
LER 99-009-00:on 990304,as-found RHR Safety Relief Valve Lift Setpoint Greater than TS Limit Occurred.Cause Investigation for Condition Has Not Been Completed.Update to LER Will Be Submitted,Upon Completion of Investigation
ML17325B5321999-04-0707 April 1999
LER 99-S01-00:on 990308,discovered That Lock for Vital Gate Leading to Plant 4KV Switchgear Area Was Nonconforming & Vulnerable to Unauthorized Access.Caused by Inadequate Gate Design & Inadequate Procedures.Mods Are Being Made to Gate
ML17325B5161999-04-0101 April 1999
LER 99-007-00:on 981020,calculations Showed That Divider Barrier Between Upper & Lower Containment Vols Were Overstressed.Engineers Are Currently Working on Analyses of Loads & Stress on Enclosures
ML17325B5491999-03-31031 March 1999
Monthly Operating Rept for Mar 1999 for DC Cook Nuclear Plant Unit 2.With 990408 Ltr
ML17325B5441999-03-31031 March 1999
Monthly Operating Rept for Mar 1999 for DC Cook Nuclear Plant,Unit 1.With 990408 Ltr
ML17325B5221999-03-29029 March 1999
LER 99-001-00:on 960610,degraded Component Cooling Water Flow to Containment Main Steam Line Penetrations,Identified on 990226.Caused by Inadequate Understanding of Design Basis.Additional Investigations Ongoing
ML17325B4801999-03-18018 March 1999
LER 99-004-00:on 971030,failure to Perform TS Surveillance Analyses of Rc Chemistry with Fuel Removed Was Noted.Cause of Event Is Under Investigation.Corrected Written Job Order Activities Used to Control SD Chemistry Sampling
ML17325B4741999-03-18018 March 1999
LER 99-005-00:on 940512,determined That Rt Breaker Manual Actuations During Rod Drop Testing Were Not Previously Reported.Caused by Lack of Training.Addl Corrective Actions,Including Preventative Actions May Be Developed
ML17325B5671999-03-0202 March 1999
Summary of Unit 1 Steam Generator Layup Chemistry from 980101 to 990218.
ML17325B4631999-02-28028 February 1999
Monthly Operating Rept for Feb 1999 for DC Cook Nuclear Power Station,Unit 2.With 990308 Ltr
ML17325B4621999-02-28028 February 1999
Monthly Operating Rept for Feb 1999 for DC Cook Nuclear Plant,Unit 1.With 990308 Ltr
ML17325B4571999-02-24024 February 1999
LER 99-003-00:on 990107,CR Pressurization Sys Surveillance Test Did Not Test Sys in Normal Operating Condition.Caused by Failure to Recognize Door 12DR-AUX415 as Part of CR Pressure Boundary.Performed Walkdown of Other Doors
1999-09-30
[Table view] |
Text
REACTOR PROTECTION AND CONTROL PROCESS INSTRUMENTATION REPLACEMENT PROJECT AT DONALD C. COOK NUCLEAR PLANT UNITS 1 AND 2 TEST PROGRAM
SUMMARY
REPORT NO. 2985-BJB-01~ REV 0 Prepared by: Date )2 i> 92 l.
Date /Z,.
92121 09 92121 PGR pSi70&~P
Reactor Protection and Control Process Instrumentation Re lacement Pro'ect at Donald C. Cook Nuclear Plant Units 1 and 2 Test Pro ram Summar Re ort No. 2985-BJB-01 Rev 0
~Sco e:
The Test Program consists of Factory Acceptance Tests (FATs),
Integration Tests, Installation Tests, Surveillance Tests and Time Response Tests for the Reactor Protection and Control Process Instrumentation Replacement Project for Donald C. Cook Nuclear Plant Units 1 and 2. The overall Test Program described below will ensure the replacement equipment will perform it' intended function within it's prescribed acceptance criteria.
This Test Program does not include the various equipment qualification tests, such as environmental and seismic tests.
These qualification tests are detailed elsewhere. Certain inspections are noted in the test summary below. Quality Control and Quality Assurance inspections performed for this project are covered under the project QA program requirements elsewhere.
Overview:
Testing will performed in hierarchial fashion to ensure that any problems which are found can be resolved before the equipment proceeds to the next phase of the project(Factory Fabrication, Plant Installation, Plant Operation). Pre-installation testing will be done via Factory Acceptance Tests and Integration Tests to ensure the replacement equipment will meet it's required function prior to actual installation. Installation tests will ensure the replacement equipment is installed according to approved design and integrated with their existing plant interfaces, such as sensors, alarms and trip functions, which are not being replaced. Post-installation Surveillance and Time Response tests will be performed to ensure the replacement equipment will meet the plant Technical Specification requirements for system operability. The replacement equipment must satisfactorily pass all of itequired tests and all problems satisfactorily resolved before the system is declared operable.
Summar Discussion:
The Test Program consists of Factory Acceptance Tests (FATs),
Integration Tests, Installation Tests, Surveillance Tests and Time Response Tests.
Factor Acce tance Test FAT Factory Acceptance Tests are pre-installation tests which verify the replacement equipment, including power supplies, interposing
Report 2985-BJB-01, Rev 0 page 2 of 5 relays, rack wiring, input and output modules and loop configurations, perform their intended function as required by both the replacement vendor and AEP design specifications prior to acceptance for delivery or installation of the equipment.
These tests are written such that a complete history of each test is documented, including a log of any discrepancies found, resolution of these discrepancies, a record of test personnel, test equipment, test setup and configuration. The final factory assembled racks which will be installed at the plant are subjected to the tests.
Temporary 120vac power is supplied to the permanent rack power supplies. The permanent rack power supplies are used to power all instrument loops. Field inputs to the rack analog input modules and output loads from the rack analog output modules are simulated using test equipment which mimic actual field conditions. The loops are configured using the controlled configuration documents which will be used for the actual installation. All inputs and outputs are tested and the overall loop configuration is verified. Dynamic and control algorithm response tests are performed to ensure their response characteristics meet the plant specific requirements. In addition, time response tests will be performed to ensure the replacement equipment will meet the plant specific time response requirements. All rack workmanship, materiel condition and wiring is also verified.
The FAT procedures are meticulously detailed. Their primary purpose is to detect any potential design, equipment or performance problems which would jeopardize plant control or protection systems from performing their intended function. All problems identified will be resolved prior to acceptance of the replacement equipment and commencement. of the installation of the replacement equipment in the plant.
Inte ration Testin The Integration Tests are pre-installation tests which ensure the Reactor Protection Group instrumentation properly interfaces with Control Group instrumentation and vice versa with no adverse interaction. These tests connect the Reactor Protection racks to the Control Group racks per the design wiring diagrams and simulate various anticipated rack interactions and perturbations, including adverse power failures, instrument groundings or failures.
The primary emphasis of the Integration Tests is to ensure that the Reactor Protection group and the Control group operate together without adverse interaction. Expected results will be
Report 2985-BJB-01, Rev 0 page 3 of 5 recorded and any unexpected results will be investigated and satisfactorily resolved prior to acceptance of the replacement equipment and commencement of the installation of the replacement equipment in the plant. These tests are written such that a complete history of each test is documented, including a log of any discrepancies found, resolution of these discrepancies, a record of test personnel, test equipment, test setup and configuration.
Installation Testin Installation Tests are performed to ensure the replacement equipment is properly installed and wired into their permanent plant mounting locations. Most of the replacement equipment will be mounted in existing racks in the control room. Some of the replacement equipment will be panel mounted on the front control panels. Some of the replacement equipment will be mounted in new racks.
Installation tests consist of initial de-energized wire continuity checks, cable meggering and visual inspections to ensure all plant interfaces such as power, grounding, field sensor inputs, trip, alarm and computer outputs are properly connected with the permanent plant equipment. Once initial checks are complete, the equipment is energized, calibrated and functionally tested to ensure all plant interfaces have been properly integrated. Inspection of the equipment installation is done to ensure the equipment is mounted in compliance with the seismically qualified mounting design.
All installation tests must be satisfactorily completed and any problems resolved before the systems can be declared operable or released for Surveillance Testing. Replacement equipment in critical plant systems whose operability is covered by Technical Specifications will not be released or declared operable until their applicable Surveillance and Time Response Tests are complete.
Surveillance Testin Once the equipment is installed and Installation Testing has been completed with all problems resolved, Surveillance Tests will be performed to ensure all applicable Technical Specification system operability requirements are met. These Surveillance Tests must be satisfactorily completed before the system can be declared operable.
Time Res onse Testin Some of the replacement equipment is integral to critical plant
~ ~ I ~
Report 2985-BJB-Ol, Rev 0 page 4 of 5 systems which are required to meet specific time response tests per plant Technical Specifications. These Time Response Tests must also be satisfactorily completed before the system can be declared operable.
For Installation, Surveillance and Time Response Tests, specific plant procedures are utilized to perform and document the tests, and to identify and document resolution of all problems.
Conclusion:
The above summary describes the various phases of the overall Test, Program. These tests are performed in hierarchial fashion to ensure that any problems which are found can be resolved before the equipment proceeds to the next phase of the project.
The tests are performed to ensure proper operation and integration of the replacement equipment in compliance with the vendor and AEP design specifications and plant functional and Technical Specification requirements.
References:
- 1. Foxboro Factory Acceptance Test Procedure for the Upgrade of the Reactor Protection Process Instrumentation TP-150, Draft Rev 2
- 2. Electrical Installation and Checkout Procedure 12 IHP 6030 IMP.59 Various Surveillance/Maintenance Test Procedures
- 3. DT/Tavg Protection Set I Calibration **2 IHP 6030 IMP.194 4; Reactor Coolant Flow Protection Set I Calibration **2 IHP 6030 IMP.199
- 5. Steam Generator Level Protection Set I Calibration **2 IHP 6030 IMP.204
- 6. Pressurizer Level Protection Set I Calibration **2 IHP 6030 IMP.208
- 7. Steam Generator 1 E 2 Mismatch Protection Set I Calibration
- 8. Steam Generator 3 & 4 Mismatch Protection Set I Calibration
- 9. Pressurizer Pressure Protection Set I Calibration **2 IHP 6030 IMP.215
Report 2985-BJB-Ol, Rev 0 page 5 of 5
- 10. Lower Containment Pressure Protection Set I Calibration **
THP 6030 IMP.219 Turbine Impulse Chamber Pressure Protection Set I Calibration **2 IHP 6030 IMP.223
- 12. Reactor Coolant Wide Range Temperature Calibration **2 IHP 6030 IMP.256
- 13. Auxiliary Feedwater To Steam Generator 41 Flow Indication Calibration **2 IHP 6030 IMP.265
- 14. Auxiliary Feedwater To Steam Generator $3 Flow Indication Calibration **2 IHP 6030 IMP.267
- 15. Steam Generator 1 6 2 Mismatch Protection Set I Transmitter Calibration **2 IHP 6030 IMP.400
- 16. Steam Generator 3 6 4 Mismatch Protection Set I Transmitter Calibration **2 IHP 6030 IMP.401
- 17. Reactor Coolant Flow Protection Set I Surveillance Test (Monthly) **2 IHP 4030 STP.101
- 18. Overtemperature and Overpower Protection Set I Surveillance Test (Monthly) **2 IHP 4030 STP.104
- 19. Pressurizer Level Protection Set I Surveillance Test (Monthly) **2 IHP 4030 STP.108
- 20. Pressurizer Pressure Protection Set I Surveillance Test (Monthly) **2 IHP 4030 STP.111
- 21. Steam Generator Water Level Protection Set I Surveillance Test (Monthly) **2 IHP 4030 STP.115
- 22. Steam Generator 162 Mismatch Protection Set I Surveillance Test (Monthly) **2 IHP 4030 STP.119
- 23. Steam Generator 3&4 Mismatch Protection Set I Surveillance Test (Monthly) **2 IHP 4030 STP.120
- 24. Containment Pressure Protection SEt I Surveillance Test (Monthly) **2 IHP 4030 STP.146
- 25. Reactor Protection 6 Engineered Safeguards System Time Response Train A Surveillance Test Procedures **2 IHP 4030 STP.100A
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