ML20133J624

Summary of 961112 Meeting W/Wog & W Re WOG Application Specific Integrated Circuit Project.List of Attendees & Copy of Nonproprietary Presentation Matls Encl

ML20133J624
Person / Time
Issue date:	01/13/1997
From:	Craig C NRC (Affiliation Not Assigned)
To:	Matthews D NRC (Affiliation Not Assigned)
References
PROJECT-694 NUDOCS 9701210080
Download: ML20133J624 (42)

Text

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NUCLEAR REGULATORY COMMISSION WASHINGTON, D.C. 2055fr0001

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p January 13. 1997 MEMORANDUM T0: David B. Matthews, Chief Generic Issues and Environmental Projects Branch Division of Reactor Program Management Office of Nuclear Reactor Regulation FROM: Claudia M. Craig, Senior Project Manager Generic Issues and Environmental Qg ,

y- l Projects Branch (

Division of Reactor Program Management Office of Nuclear Reactor Regulation

SUMMARY

OF MEETING WITH THE WESTINGH0USE OWNERS GROUP (WOG) AND WESTINGHOUSE REGARDING THE WOG APPLICATION SPECIFIC INTEGRATED CIRCUIT (ASIC) PROJECT The subject meeting was held at the Westinghouse Rockville Nuclear Licensing Center in Rockville, Maryland on November 12, 1996, between representatives of Westinghouse, the WOG, and the NRC staff. The purpose of the meeting was to discuss the WOG project regarding ASIC-based reactor control and protection system replacement modules for Westinghouse designed nuclear units.

Attachment 1 is a list of attendees. The proprietary and non-proprietary versions of the presentation material were provided in a letter dated December 12, 1996. Attachment 2 is a copy of the non-proprietary presentation materials.

The first part of the meeting involved a presentation by the WOG on the design of the 7300 ASIC card. The 7300 ASIC card is intended to be a one for one replacement card for the existing analog 7300 card. The WOG provided an overview of the design process which outlines the requirements of the existing )

analog 7300 card and proceeds through the translation to digital format, the fabrication process, and testing. The QA process and the testing criteria were also described. l l

It is the W0G's intention that WOG members install the replacement cards under  !

10 CFR 50.59 without plant-specific NRC approval. This requires the utility l to make the determination that there is no unreviewed safety question as i described in the rule. The W0G was interested in finding out if the staff would agree that a licensee could make such a determination and install the ASIC card without prior NRC approval. One of the significant areas of discussion was the potential for a common-cause failure. The ASIC design h

involves significant use of software-based tools for the design and l

fabrication of the chip. The staff has previously taken positions that

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9701210080 970113 g esos eoe 3.

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. l D. Matthews January 13, 1997

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software-based systems, microprocessors and programmable logic controllers in safety-related instrumentation and control systems should be considered vulnerable to a software common-cause failure and specific diversity and defense-in-depth considerations need.to be addressed. Because this is considered a malfunction of a different type than previously analyzed, the staff has stated that software-based microprocessor replacements of analog systems may present an unreviewed safety question.

i The WOG presented a list of reasons why an ASIC design is not . subject to i common-cause failures similar to microprocessor designs. These included simplicity of design, a robust design process, and most importantly, the testability of the final product. The WOG stated they intend on performing a i large number of tests to demonstrate the functions ~of the device and additional tests which will test almost every possible electrical path on the chip. The WOG stated this extensive testing eliminates the consideration of the software-based design tools as a source of common-mode failures and, therefore, there should not constitute an unreviewed safety question related

{ to the ASIC itself (the plant would still need to review the specific l application). The staff stated the testing could be used to demonstrate the l software-based tools do not introduce common-cause errors that would not be l detected by testing. In so doing, the WOG would show the ASIC common-mode failure is no more likely than a common-mode failure in the original analog system it replaces. The staff stated that if the testing is shown to be J

sufficient and the other design considerations as presented by the WOG are carried out, the topical report describing this design could be used as the basis for a utility to make the plant-specific determination under l 10 CFR 50.59 that the 7300 ASIC card design does not create an unreviewed '

safety question.

The staff discussed the status of an ongoing research project on ASIC, 4

sponsored by the staff. The staff stated that they will provide a summary of l the research status to date to the WOG and, when available, will provide a  !

copy of the research results.

i The WOG and the staff discussed the EMI qualification of the ASIC card. The

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WOG's stated intention was to qualify the card to the same levels using the same tests as for the analog 7300 card. The staff stated it would be difficult to show that the spectrums tested would be appropriate due to the change in technology and the different frequency susceptibilities. The WOG asked the staff if it was the staff's understanding that if the ASIC was qualified in accordance with the EPRI EMI guidance document (TR-102323), the EMI qualification requirements would be satisfied. The staff stated that was their understanding.

The schedule for submittal of design information was also discussed. The proposed schedule includes the first topical report section being submitted in March 1997 and a demonstration project and the staff providing its topical safety evaluation report in November 1997. The staff. discussed the expected

D. Matthews -3_ January 13, 1997 review process which will involve review of the submitted topical report and i supporting documentation as well as audits of the design, fabrication, and  !

testing process and results. The staff agreed to a future meeting prior to  !

the start of the formal submittals to work out review details.

Project No. 694 Attachments: As stated cc w/atts: See next page

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D. Matthews Uanuary 13, 1997 review process which will involve review of the submitted topical report and supporting documentation as well as audits of the design, fabrication, and testing process and results. The staff agreed to a future meeting prior to the start of the formal submittals to work out review details.  !

Project No. 694 Attachments: As stated cc w/atts: See next page DISTRIBUTION:

See attached page DOCUMENT NAME: ASIC2. MIN To seceive e copy of this document,Indcate in the boa: "C" = Copy without ettschment/ enclosure "E* = Copy with ettschment/ enclosure

• N" = No copy

'See previous concurrence ((, /

OFFICE PGEBru i A SC:PGEB BC:HICB BC:PGEB ( ///

NAME CCraigfsd L RArchitzel* JWermiel* DMatth6s/ff!

DATE 1/(.3/97 12/26/96 12/27/96 1/H /97'~^

OFFICIAL REC 0ilD COPY 1

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I

l DISTRIBUTION w/ attachments: Summary of November 12, 1996, with Westinghouse dated January 13, 1997

- Central File PUBLIC PGEB RArchitzel CCraig f-Mail FMiraglia/AThadani RZimmerman TMartin GHolahan BSheron BBoger JWermiel DSpaulding JMauck JStewart 1

210022

i WOG / NRC MEETING NOVEMBER 12, 1996 MEETING PARTICIPANTS N8ME ORGANIZATION l l

Steve DiTommaso WOG Project Office l Jim Fulford LIS  !

Michael Marino VA Power l Bob Cockrel TU Electric l Jared Wermiel NRC Joseph Naser EPRI Deidre Spaulding NRC Jerry Mauck NRC Jim Stewart NRC Darrell Cooksey Union Electric Co. ,

Karl Jacobs NY Power Authority l Andred Petrenko NY Power Authority '

Paul Travis Houston Lighting & Power i Bob Queenan Duke Power l Ron Battle ORNL Dick Miller Westinghouse Carl Vitalbo Westinghouse NSD Bob Sterdis Westinghouse NSD Dennis Deardorff SCE&G ATTACHMENT 1

weatinghoune Non. Proprietary class 3 j

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l Westinghouse Owners Group - EPRI l VIeeting with the L'S NRC j on ASIC Based Reactor Control &

l Protection System Replacement VIodules for Westinghouse Designed Nuclear L nits l November 12,1996 i

I Westinghouse Rockville Licensing Office l Rockville, MD t 1996 We thw IIntsic C s pornha 4

Attachment 2

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i Meeting Date: November 12, 1996 I

. Meeting Time: 8:00 AM - 1:00 PM Meeting Place: Westinghouse Rockville Licensing Office

Participants:

Mike Marino, ASIC Steering Committee Chairman, VP a Darrell Cooksey, Union Electric j Bob Queenan, Duke Dennis

Deardorf,

SCE&G Mike Murray, HL&P Paul Travis, HL&P Bob Cockrel, TU .

Joe Naser, EPRI l Bob Sterdis, Westinghouse Carl Vitalbo, Westinghouse Ron Battle, ORNL NRC: Jim Stewart Jerry Mauck Jerry Wermeil Agenda:

8:00 AM - 1:00 PM I. Design Status I hr.

II. Licensing Approach I hr.

III. Elements of Licensing Strategy I hr.

IV. Identification of Licensing Issues 2 hrs.

to be Addressed in Topical Report Objectives:

(1) Gain agreement with NRC on licensing approach (schedule, fees, topical content, SER, what will NRC review against).

(2) Gain agreement with NRC on licensing issues.

(3) Inform NRC of design status. .

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Licensing Approach - - -

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i a WOG will submit Topical Report to the NRC via formal WOG letter.

) o Topical Report will contain proprietary information and will j be accompanied by an application for withholding and i

affidavit.

j a Topical Report will be transmitted piecemeal by section.

o Key elements of submittal:

l l + Test program results (component, card) i

+ FMEA i + EMI/RFI emissions / susceptibility

+ EQ program results

+ 10CFR50.59 evaluation j + Regulatory criteria compliance

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Schedule: W83 l

m issue Letter on Intent to Submit Topical 1/97 j u issue First Topical Report Section 3/97 m issue Final Topical Report Section 4

4 9/97 j u issue Final Version of Topical Report 9/97 l

t NRC issues SER 11/97

= South Texas Demonstration l

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] + Plants implement Replacement Cards Under One Time i 10CFR50.59 (Equivalency Evaluation) and Treat As I

Spare Part.

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Elements of Design Program that E03

Support Licensing Under 10CFR50.59 ~ **

! Testability i

liardware Based w/o Software Selection ofIlighly Reliable Replacement Components End User input Throughout Development Program Vendor Experience &

Qualifications Robust Design Process

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the Design Process ---

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l l m The Robustness and Integrity of the ASIC Replacement l Module Design Process Provides for Extremely High Confidence that the Performance Requirements have been

Properly Translated to Data Flow Diagrams, Mnemonic l Instructions have been Correctly Specified and Interpreted

. to Control Codes, and All Math and Process Functions have

been Exhaustively Tested.

i a Test Vectors were Developed Jointly Between Independent l Organizations, ATC and ORNL. Tests were Applied to Actual Devices and the Results were Compared to i

4 Simulation Test Results.

j u Example: ASIC Controller Design Process S I

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i Vendor Experience and Qualifications I*D

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! o Westinghouse is the Original NSSS Plant Designer, l the OEM Supplier of the 7300 Process System, and an '

) Appendix B Supplier with over Thirty Years of Design and Licensing Experience.

i o ATC is a Supplier of Military Components Commonly j Used in Safety Critical Applications. ATC has l Extensive Experience in the Design and Application of j Custom Integrated Circuit Technology.

i o ORNL l + National Lab i

! + ASIC Experience includes Designs for Private Industry, j Universities, European and U.S. Labs (Physics Experiments)

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+ Developed Prototype under CRADA with EPRI

+ Process Control Experience

End User input Solicited

~gg3 l Throughout the Design Process ~-~

i i a Hundreds of Man-Years Operating Experience and System Knowledge.

l = Operator Interface Minimizes impact on Plant

Staff and Training.

= Utilities have Extensive Design Basis Knowledge.

l m Close Utility-Vendor Relationship Provides for

Successful and Stable implementation.

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Reliable Technology and g,3 Components ----

l m ASIC Chip Technology (1 micron) has Demonstrated i

Reliability on the Order of 1 x10-7 Failures per Year. '

i e ASIC Mother Board Components Selected for a MTBF of 50,000 Hours.

a FPGA's Reliability Database Shows Failures on the Order of 1 x 10-7 Failures per Year.

i a Components are Selected to have Higher Performance

Specifications than Analog Board Components.

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l WG Hardware Based Solution ~---

o Hardware is Effectively Distinguished from Software when a l Model can be Constructed for All input / Output States, and a l Device is Comprehensively Tested.

j o The ASIC based replacement module does not contain software j

or programmable (modifiable) code. '

a Each Control Code Enables a Specific Dedicated Math Circuit or j Function in the ASIC.

l ~+ The ASIC Circuits are not Programmable.

j 4

+ The ASIC Chip is a Dedicated Component.

l o Controller Operation is Deterministic and Sequential, No I interrupts.

l o The System Makes No Decisions on input Data. There is No Branching or Alternate Signal Paths.

j a The System Cannot Halt or Lock-Up.

l 0 Failure of the Clock Circuit is Detectable and Results in an Alarm.

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l WeD S.imple and Testable Design ----

l l m The ASIC Based Replacement Module is Pin-for-Pin Compatible j With the Module it Replaces.

j u No Internal Cabinet Wiring Changes are Required for the Card-for-l Card Replacement Option.

j = The ASIC Module Architecture implements Standard Math  ;

i Functions: Add, Subtract, Multiply, Divide, Square Root, Compare and Function Generator.

j u Basic Math Functions are Standard, Simple, and Well Understood.

a Simple Math Functions can be thoroughly tested.

i + Simulation Tests are Performed at Each Design Stage, and are Repeated on the Fabricated ASIC.

+ The ASIC Design is Completely Testable at the Component Level (100% Fault Coverage).

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l Simple and Testable Design g,3 (Cont.) --~

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l a A Controller PROM Wi!! Enable the Standard Math l Functions in the Correct Sequence to Perform Process j Functions.

o in the ASIC Replacement ~ Module Application, each Control i

Code has a Direct Correlation to a Unique Mnemonic

instruction. This Design Characteristic Allows for a 100%

Validation Verification of the Controller instructions to the

! ASIC Chip.

h a Process Functions are Completely Verified and Tested.

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l ASIC Replacement Module I Regulatory Requirements

{ Compliance 1

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REGULATOR.Y REQUIREMENTS l m ACCEPTANCE CRITERIA

! + 10 CFR Part 50 - Domestic Licensing of Production and l Utilization Facilities.

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+ 10 CFR Part 50, Appendix A, General Design Criteria for Nuclear Power Plants.

+ 10 CFR Part 50, Appendix B, Quality Assurance Criteria for

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Nuclear Power Plants and Fuel Reprocessing Plants.

m REGULATORY GUIDELINES

! + RG 1.22 Periodic Testing of Protection System Actuation Functions.

+ RG 1.47 Bypassed and Inoperable Status Indication for '

{ Nuclear Power Plant Safety Systems. i j + RG 1.53 Application of the Single-Failure Criterion to l Nuclear Power Plant Protection Systems.

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Regulatory Requirements (Cont.)

u REGULATORY GUIDELINES (Cont.)

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+ RG 1.62 Manual Initiation of Protection Actions.

! + RG 1.75 Physical Independence Of Electric

) Systems. -

+ RG 1.97 Instrumentation for Light Water Cooled l Nuclear Power Plants to Assess Plant i

Conditions.

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~+ RG 1.105 Instrument Spans and Setpoints.

+ RG 1.118 Periodic Testing of Ele'ctric Power and l Protection Systems.

l + RG 1.151 Instrument Sensing Lines.

l + RG 1.152 Digital Computers in Safety Systems of

{ Nuclear Power Plants.

l + RG 1.153 Power Instrumentation and Control 1

Portions of Safety Systems.

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W8D Draft Regulatory Guidelines J

l l m The ASIC Replacement Module Application is Viewed as an i

implementation of a Hardware (Completely Testable) Technology. As Such, the Draft Regulatory Guidelines on Software Used in Safety Systems are Not Directly Applicable. However, the Design Process for i the ASIC Based Replacement Modules Exhibits Many Consistencies with j the Software V&V and Development Processes Endorsed by DG-1054 and

DG-1059.

j u DG-1054 Verification, Validation, Reviews, and Audits for Digital l Computer Software used in Safety Systems of Nuclear Power Plants.

l Endorses IEEE Std 1012-1986 and IEEE Std 1028-1988.

! e DG-1055 Configuration Management Plans for Digital Computer l Software used in Safety Systems of Nuclear Power Plants."

l

, Endorses IEEE Std 828-1990 and ANSillEEE Std 1042-1987.

e DG-1056 Software Test Documentation for Digital Computer Software

used in Safety Systems of Nuclear Power Plants.

Endorses ANSl/IEEE STD 829-1990. '

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l Draft Regulatory Guidelines gg l

i (Cont.) --~

m DG-1057 Software Unit Testing for Digital Computer Software i

i used in Safety Systems of Nuclear Power Plants.

Endorses ANSillEEE Std 1008-1987.

) m DG-1058 Software requirements Specifications for Digital Computer Software used in Safety Systems of

) Nuclear Power Plants."

Endorses IEEE Std 830-1993.

a DG-1059 i

Developing Software Lifecycle Processes for Digital Computer Software used in Safety Systems of l Nuclear Power Plants.

l Endorses IEEE Std 1074-1995.

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Identification & Discussion of l Licensing issues i

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! Summary of NRC Concerns (as l understood by WOG ASIC E83

~'

l Steering Committee) i i

! a Thorough description of testing at all levels (3/96).

a Common mode failures at system level (3/96).

]

= Chip quality controls (3/96).

a Proper translation of 7300 requirements (3/96).

m VN of software design and validation tools (3/96).

! m Software issues applicability to ASIC chip (3/96?.

a Power supply impacts effects of power quality j (3/96). .

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L :::: - _ _ _ - _ _ - _ -__

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cc:

Mr. Nicholas Liparulo Westinghouse Electric Corporation Mail Stop ECE-4-15 P.O. Box 355 Pittsburgh, PA 15230-0355 Mr. Hank A. Sepp Westinghouse Electric Corporation Mail Stop ECE-4-07A P.O. Box 355 Pittsburgh, PA 15230-0355 Mr. Andrew Drake, Project Manager Westinghouse Owners Group Westinghouse Electric Corporation Mail Stop ECE-5-16 P.O. Box 355 Pittsburgh, PA 15230-0355 Mr. Mark Beaumont Westinghouse Electric Corporation One Montrose metro 11921 Rockville Pike, Suite 450 Rockville, MD 20852

,