ML20094R367

Forwards 4-yr Rept of Training Simulator,Per 10CFR55.45

ML20094R367
Person / Time
Site:	Callaway
Issue date:	11/27/1995
From:	Schnell D UNION ELECTRIC CO.
To:	NRC (Affiliation Not Assigned), NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
ULNRC-3293, NUDOCS 9512040376
Download: ML20094R367 (11)

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. Office of Nuclear Reactor Regulation Attn: Document Control Desk Mail Stop P1-137 Washington, DC 20555 ULNRC - 3293 Gentlemen:

DOCKET NUMBER 50-483 i

CALLAWAY PLANT CALLAWAY PLANT SIMULATOR 4-YEAR REPORT In accordance with 10 CFR 55.45, we herewith submit the 4-Year Report of Union Electric Company's Callaway Plant Training Simulator.

l All required tests have been successfully completed in accordance with the testing plan.

If there are any questions concerning this report, please contact us.

Very truly yours,

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Office of Nuclear Reactor Regulation 4 U. S. Nuclear Regulatory Commission Mail Stop Pl-137 Washington,DC 20555 L. J. Callan USNRC Region IV - Regional Administrator U. S. Nuclear Regulatory Commission Region IV 611 Ryan Plaza Drive, Suite 400 Arlington, TX 76011-8064 D. G. Passchl USNRC Resident Inspector Callaway Nuclear Plant P. O. Box 620 Fulton, Missouri 65251 l

i L. R. Wharton l

USNRC Licensing Project Manager, Callaway Plant j

Office of Nuclear Reactor Regulation U. S. Nuclear Regulatory Commission i

Mail Stop 13-E-21 Washington,DC 20555 i

Manager, Electric Department l

Missouri Public Service Commission P. O. Box 360 Jefferson City, MO 65102 Thomas A. Baxter Shaw, Pittman, Potts & Trowbridge

' 2300 N. Street N. W.

Washington,DC 20037 l

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1

CALLAWAY PLANT SIMULATOR '

4 YEAR REPORT L-Introduction The Callaway Plant Simulator 4 Year Repon is a supplement to the Simulation Facility Certification form (NRC Form-474), the Simulator Annual Reports and Simulator operating procedures. This report briefly provides a description of the simulator, the Certification Checklist and the current status of the Configuration modifications. Additional information conceming specific tests is available upon request.

IL SimulatorInformation Simulator Type:

Reference Plant Simulator Manufacturer:

Westinghouse Electric Corp.

Owner / Operator:

Union Electric Company

- Reference Plant:

Callaway Plant Plant Location:

Fulton, Missouri

' Plant Type:

Pressurized Water Reactor Plant Rating:

3565 Megawatts thermal Date available for training:

February 1982 Type ofreport:

4 Year Repon IIL Simulator Procedures The Simulator is controlled, operated, tested and modified utilizing the following Callaway Plant procedures:

APA-ZZ-00021 Conduct of Operations-Training TDP-IS-00001 Callaway Plant Simulator Operation and Maintenance TDP-IS-00002 Simulator Configuration Management TDP-ZZ-00009 Course Deficiencies

' 4 Year Report 1

November 30,1995 CALLAWAY PLANT SIMULATOR 4 YEAR REPORT IV. Simulator Database Controlled drawings and procedures are used as a basis for handler logic and system flow calculations. The Callaway Equipment list, the Plant Engraving list, and Plant computer logs are also used as inputs for the Simulator data base. Plant logs are used whenever possible to compare Callaway Plant data to Simulator response to ensure that the Simulator data base closely matches the plant. Feedback from Plant operators, using the Configuration Control process, is also an essential part ofmaintaining the Simulator up-to-date with the Plant.

V.

Major Changes Since Last Report The following are the major items that were changed on the simulator:

- Added controls on the Auxiliary Shutdown panel panels RP118A and RPl18B

- Added controls on the ventilation control panel RP068

- Replaced the Gould 32/8750 computer with an ENCORE RSX computer

- Added a stimulated plant computer system on a DIGITAL VAX 3800 computer

- Replaced Main Control Board recorders with Chessel recorders

- Replaced the positive displacement charging pump with a centrifugal charging pump

- Retired the BIT in place and realigned flow through a Boron Injection Header

- Removed the Containment Spray Surge tank.

- Replaced the Radiation Monitoring panel CRT with a personal computer

- Added RM11 Printer capability

- Added capability for RCS Midloop LevelIndications

- Changed many lamacoid engravings during human factors review A total of 623 SIFT items were tested from December 1991 through November 1995.

4 Year Report 2

November 30,1995 CALLAWAY PLANT SIMULATOR I

4 YEAR REPORT i

VI. Outstanding Plant Modification Items SIFT 92-03-06 SG N 16 DETECTOR REFERENCE RFR 10301 A, MP 92 3014, MP 93-1060 This item is still an open plant modification. The RFR that controls this item is anticipated to bc j

completed in the plant during November of 1995. The SIFT is in the process of being completed at this i

time.

i SIFT 93-05-22 RADIO SYSTEM UPGRADE REFERENCE RFR 14870 MP 94-1016 This item is still an open plant modification. The plant radio upgrade is in progress. Some items have been installed for trial implementation in the plant and on the simulator. This modification is not completed in the plant, awaiting a software correction for the main computer controlled radio console.

VII. Certification Testing Checidist The attached Callaway Plant Simulator Certification Checklist No.1, Attachment 1, indicates the completion of the required performance tests. Specific testing data is available upon request.

i The Callaway Plant Simulator Certification Checklist, Cenification Tests and Configuration Control Tests that were performed during the previous four years have been l

i reviewed and accepted, meeting the testing requirements of 10CFR55.45, Reg. Guide 1.149 -

3 1987 and ANSI /ANS-3.5-1985.

4 M M ate: //!2 h 6 Senior Training Supervisor, Simulator I

Certification tests are divided into three distinct groups:

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Annual Tests-performed each year Yearly Tests - 25% perfomied during this year l

Random Tests - verify operation of various instmetor interface features i

i VIII. SimulatorTesting Plan i

The projected Callaway Plant Simulator Testing Plan, Attachment 2, indicates the Configuration modification tests and Cenification tests to be completed. The plan also identifies the four year testing schedule from January 1996 through December 1999 l

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November 30,1995 CALLAWAY PLANT SIMULATOR 4 YEAR REPORT VIX. Documentation The summary of all simulator tests that have been performed during any specific year

, are documented in the Simulator Annual Report. This report is maintained on-site as a QA record. The individual certification tests contain the detailed testing documentation information required in ANSI /ANS 3.5 - 1985 Appendix A, Nuclear Power Plant Simulators for use in Operator training. The individual certification tests are also maintained on-site as QA records.

X. References

-Title 10, Code of Federal Regulations, Part 55, " Operator Licenses"

-American National Standard Nuclear Power Plant Simulators for Use in Operator Training, ANSI /ANS-3.5-1985

-U. S. Regulatory Commission Regulatory Guide 1.149, " Nuclear Power Plant Simulation Facilities for use in Operator License Examinations", April 1987.

4 Year Report 4

' TDP-IS-0' 0002 I

i Rev. 2 Checkoff List No.1 1

Page1of4 1

Person (s) Completing Checkoff Initials CALLAWAY PLANT SIMULATOR List (Print)

CERTIFICATION 30M R. R%TMAN g/#

CnECx tiST FOUR NEAR SUBWt IW -ITIS Date/ Time Started 9//2 #

GGGG DatefTimeCompleted 9f//JG 2359 1.

ENVIRONMENTAL EVALUATION 1.1 CONTROL ROOM i

NOTE. These items are reviewed on a 4-year cycle. The performance is required only for the year in which they are scheduled if the control room was modified and an evaluation indicated that the item had a training impact.

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1. Obtained latest revision copy ofReference Plant Control Room floor plan. Obtained drawing ofReference Plant Simulator control room floor plan. A comparison of the 4

floor plans was completed. A list of difference is available for inspection.

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2. Compared lighting in the plant and simulator control rooms. A list of differences is i

available for inspection.

3. Communications systems available in the plant and simulator control rooms have been compared. Differences are indicated on the attached list.

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4. Furnishings in the plant and the simulator have been reviewed. A list of differences is attached.

1.2 CONTROL PANELS NOTE. These items are reviewed on a 4-year cycle. The performance is required only for the year in which they are scheduled if the control panels were modified and an evaluation indicated that the item had a training impact.

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1. Pictures of the Reference Plant Main Control Boards have been taken. Pictures of the Reference Plant Simulator Main Control Boards have been taken. A comparison of the pictures was completed. The pictures are available for inspection.

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Checkoff List No.1 Page 2 of 4

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2. The control panels have been verified to be correct as compared to the plant engraving list. The engraving list is available for inspection.

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3. The simulator will support the plant computer keyboard functions identified on the attached list.

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4. l The simulator will support the plant computer displays identified on the attached list.

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The simulator will support plant computer trending capabilities identified on the attached list, f '/

6. The simulator will support the plant computer alarm displays identified on the attached i

list.

1.3 SPECIAL FEATUIGS NOTE: This item is reviewed on a 4-year cycle. The performance is required only for the year in which it is scheduled.

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1. Special features available on the Callaway Plant Simulator are indicated on the attached list.

2.

REAL TIME VERIFICATION i

NOTE: This item is performed on a 4 year cycle. The performance is required only for the year it is scheduled in.

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I. The simulator runs in real time.

3.

STEADY STATE OPERATIONS 3.1 INITIAL CONDITIONS i

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1. For each initial condition to be certified technical specification logs have been taken and

- are available for both the plant and the simulator.

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2. Heat Balances have been performed at 50%,80%, and 100% Initial conditions.

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3.2 STEADY STATE STABILITY f/d

1. Stability tests have been performed at 100% Initial conditions.

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Rev.' 2 Checkoff List No.1 Page 3 of 4 i

4.

. NORMAL OPERATIONS J

NOTE: These items are performed on a 4 year cycle. The performance is required only for the year they are scheduled in.

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1. Normal plant operations are performed during the control board certification course.

Problems identified via feedback from instructors and students are either corrected!

indicated on the attached list.

2. All applicable suneillance procedures were performed on the simulator. Problems identified via feedback from instructors and students are either corrected or in the attached list.

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TRANSIENTS

1. Transients listed in Appendix B of ANSI /ANS-3.5-1985 have been graphed on the simulator. The tests have been reviewed by the SCRG. Problems identified have either been corrected or are identified on the attached list.

l 6.

SIMULATOR OPERATING LIMITS l

i NOTE: This item is reviewed on a 4-year. The performance is required only for the

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year in which it is scheduled if the operating limits were modified and an 1

evaluation indicated that the item had a training impact.

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1. When parameters monitored on the SPDS panel are exceeding the expected values on amber light is displayed on the panel warning operators that an unusual condition exists and that indications can no longer be relied upon.

7.

INSTRUCTOR INTERFACE 4

7.1 MALFUNCTIONS NOTE These items are performed on a 4 year cycle. The performance is required only for the year they are scheduled in.

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1. 25% of all ANSI 3.1.2 MALFUNCTIONS have been tested. The tests have been reviewed by the SCRG. Problems identified have either been corrected or are identified on the attached list.

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7.2.

LOCAL OPERATOR ACTIONS f

1. Random selection testing has been conducted to validate the operability orlocal f

operator actions. The tests have been reviewed by a committee with members from operations, engineering and training. Problems identified have either been corrected or j

are identified on the attached list.

7.3 PLANT PAP.AMETERS

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1. Random selection testing has been conducted to validate the operability oflocal l

I operator actioris. The tests have been reviewed by a committee with members from i

operations, engineering and training. Problems identified have either been corrected or arc identified on the attached list.

7.4 BISTABLES f4

1. Random selection testing has been conducted to validate the operability oflocal operator actions. The tests have been reviewed by a committee with members from l

operations, engineering and training. Problems identified have either been corrected or are identified on the attached list.

7.5 ANNUNCIATORS I

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1. An automatic testing sequence has been conducted to validate the operability of the f

annunciators. The tests have been reviewed by a committee with members from i

operations, engineering and training. Problems identified have either been corrected or i

are idercified on the attached list.

7.6 COMPONENT OVERRTE fM

1. Random select on testing has been conducted to validate the operability oflocal i

operator actionc. The tests have been reviewed by a committee with members from

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operations, engit eering and training. Problems identified have either been corrected or are identified on the attached list.

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CALLAWAY PLANT SIMULATOR TESTING PLAN JANUARY 19W DECEMBER 1999 f

JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER 1996l-

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-i fBIEEErfE CONFIGURATION TESTING SCHEDULE 4 YEAR

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-I Shift Development to Training

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-iMajor hardware changes Irmmitti initial conditions snapshots JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER 1996 l-

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'l CERTIFICATION TESTING SCHEDULE 4 YEAR

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- I snopshot & log testing i :.

steedy state & heet belance testing I i normel operetions & transient testingM instructor interface le sting 1.

I correchons testing M ontrol roern evaluabon l a, u-l plant slide review ;g.M.:. engraving list review in %n I plant computer cepabitrties E specin! fentures t

real-time testingi.

I prepare simulntor Annunt Certificntion report

• NOTE:The actual schedute meyvery due to Plant outages however, all required testing will be performed prior to submittet of the Simulator Annuel Certificebon Report.

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