ML20197C699

Preliminary Deterministic Failure Consequence Analysis for Non-Nuclear Instrumentation (Nni) & Integrated Control Sys (ICS) Power Supply Failure

ML20197C699
Person / Time
Site:	Rancho Seco
Issue date:	07/25/1986
From:	Ford B, Johnson P, Spencer B SACRAMENTO MUNICIPAL UTILITY DISTRICT
To:
Shared Package
ML20197C690	List: ML20197C682 ML20197C699 ML20197C704 ML20197C712 ML20197C721
References
TAC-61631, NUDOCS 8611060359
Download: ML20197C699 (26)

Text

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'O otTra*1NtSTic F^1tuRE c0NStoutNCt ANAtv515 FOR NON-NUCLtAR INSTRUMENTATION (NNI)

AND INTtGRATtD CONTROL SYSTtM (ICS)

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POWtR SUPPLY FAILURE (o. -

Team Leaden Team m n Bill Ford LJT Bill Soencer

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Paul Johnson P.fke Roias .

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Larry Wittrue l July 25,1986

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13611060359 861030 PDR ADOCK 05000312 P PDR t

Attachment 1.lg-1 31 pages I

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9 PURPOSE OF THE REVIEW h

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~ The effect of less cf !.C zad CC pcwcr ::;plie: te !!!: /ICS instrumentation and process control schemes nave been evaluatec. From tnese evaluations tne individual component failure modes and associated plant response was determined.

Based on the evaluations and ceteminaticn:, :pecific recommendation: can be ~

made to improve plant reliability for operations or ensure the plant is brought to a known, safe condition following a trip initiated by loss cf one of the several NNI/ICS power supplies.

A review of ICS input / outputs parameter, failures was performed. This  !

established a high level confidence that the BAW 1564 of August 1979 ICS l

Reliability Analysis, correctly predicts Rancho Seco plant response to single failure criteria. A second reliability study is being perfonned by the BWOG '

as a part of the Stop-Trip program.

SUMMARY

OF RESULTS L ICS (Less of ICS AC or DC power).

• l The ICS is one of several process systems driven by the NNI. As shown in electrical schematic N21.01 - 65/4, AC power is provided by Yital Inverter 1C and backed up by Reactor Plant Bus .N via an Auto Transfer Switch. DC power I is provided by redundant i 24V.DC supplies.

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Input power supply failures should not effect ICS operation (loss of one

'O inverter or one 124v oc suppiy). sowever tne 12-26-85 transient cieariy snows that redundant power supplies can be lost.

Since ICS control power is 124V DC, the failure code f s C Y DC and most processes controlled by this DC power are driven to 50% of range (i.e., valves run to 50% open, meters run to 50% of scale). An exception to this is MFP speed, which i's driven below minimum speed, 2600 P.PM.

ICS AC power is utilized to drive a series of steam and feedwater control ,

valves in addition to a modest number of process instruments. These instruments fail to 50% of range and.the valves either fail as is or respond to DC control at a reduced rate.

(D. it shouid be noted that los, of 1CS (o, ,,1) oc , we, .ithout loss of the associated AC power is a plausible. failure. Loss of ICS (or NNI) AC power without loss of DC power is an unlikely failure.

Only a major change to the entire ICS control scheme will alter the ICS failure modes. Therefore, a series of modest control modifications have..been initiated or are recomended by this report to ensure tne plant is brougnt to _

a known safe condition (Hot Shutdown) on loss of ICS AC or DC power.

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h ICS (loss of NNI AC or DC power)

The NNI has three DC power supplies and four AC power supplies. Details of these power sources are discussed elsewhere is this report. .

The NNI provides 23 process inputs to the ICS. Each has failure modes based on loss of one or more of the several power sources. In a number of cases this results in multiple failure modes. Details of each failure mode and i plant response are shown in matrix fom as attachments to this report.

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l Of the 23 NNI process inputs to the ICS', '12 can result in a plant trip as a result of losing one of the AC or DC power supplies. Most frequently this

% trip is the result of BTU limit protection.resulting from a real or indicated 4

mismatch between feedwater and reactor. due to the power supply failure (feedwater flow reduction resulting in a high pressure reactor trip).

Following loss of an AC or DC power supply that results in a plant trip, the potential exists .for steaming one, or both OTSG's dry due to 4 of the 23 inputs from NNI to ICS. .

The ICS review revealed the Auxiliary Feedwater System (AFW) is initiated on each reactor trip. This action is due to a recent change to Main Feedwater Pump minimum speed setting .in respoitse to an NRC concern regarding AFW Auto-start control.

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rQ NNI (loss of X or Y AC or DC power, loss of Z DC =cwer, !.c:s of H4SC-A or B AC power) .

As shown in electrical schematics N15.07-57, 58, 59, 60 and 81 AC power is provided to the NNI System by Vital Inverter ID and backed up by Reactor Plant l ' Bus 1J via an Auto Transfer Switch. DC power is provided by redundant 124 Y DC supplies. An additional source of AC power is provided from Vital Inverters 1A and IB via Rochester Instrument System (RIS) cabinets H4SCA and H4SCB.

As stated in the ICS section above, los's of one inverter should not effect NNI T

outputs. However experience has shown the DC power sources to have a greater likelihood of total failure than that of AC power source total failure.

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A large number of Control Room instruments and process controls (but by no means all) are directly effected by loss of one or more of the NNI power supplies.

In addition, some inputs to the SPDS are effected by these power losses. .

.These SPDS points are identified as 9000 series computer points in the attached instrumentation / process matrices.

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1 ICS is the major process effected by NNI power supply losses. In addition, pressurizer level, spray and heater controls; letdown, purification, makeup flow and critical filter differential pressures; reactor coolant pump seal ,

flow and data; and a large number of secondary plant instruments and controls are effected by NNI power supply failures.

With very few exceptions, on loss of NNI DC power resulting in the les:; cf a process control (a valve fails to 50%' open), the associated process instrument l 'nonnally used by the operator also fails to 50% of range. The effected ,

system (s) is driven into a transient that can not be monitored by the operator.

i Detailed data sheets listing the proc,ess control and/or instrumentation signal are enclosed in this report. These dat'a' sheets correlate each detection device (temperature, flow, etc.) with its power supply and briefly sumarizes the failure mode and plant impact. .

METHODOLOGY Current NNI/ICS electrical schematics have been color coded and traced from signal source to instrument or process response. The unique failure modes that occur on loss of individual power supplies required a multiple color _

coding system to distinguish between total failures, potential failures (based on operator selection options) and non-failures.

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'O ^ eink-Green-Biue coior cooe nas been used to show:

Pink (P) -

Instrument or process is invalid due to power loss .

Blue (B) -

Instrument or process is not effected by the power loss i

Green (G) -

Based on operator selection, instrument or process will be invalid or uneffected, by the power loss. ,

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i The tri-color scheme was used to trace faults due to loss of NNI X, Y and Z DC _

i power and RIS A and B power. Loss of NNI X and Y AC power and ICS AC power were yellow lined to ensure each instrument or control was reviewed.

A complete set of color coded NNI/ICS drawings are attach.ed to this report.

Nuclear Engineering's drafting group has demonstrated a satisfactory method of reproducing these. color codes drawings with " black shaded" tape if multiple j copies of these prints are deemed necessary.

For purposes of evaluation, the plant was assumed to be at full power when the .

power supply failure occurred. Therefore, if a plant trip is involved, it is assumed to be the direct results of the specific power failure. There are four exceptions to this guideline mode in the general failure matrix. These are failures that can occur but do not of themselves trip the plant. However if a plant trip does occur for any reason when these failure (s) are in effect

, it could lead to a dry OTSG. Each of these four failures are associated with OTSG Startup or Operata level signals. -

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ECOMMENDATIONS

, i It is the consensus of the Review Tea: that loss of NNI or ICS indivicual DC power supplies are the most plant limiting because of their greater likelihood l of failure. Loss of NNI, RIS or ICS AC power does inhibit plant operation, impact process instrumentation and can result in a plant trip. Planned modifications to the AC power sources, to be completed before plant startup, further secures these power sources.

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Based on this consensus, recommendations for modifications to NNI/ICS power supplies and control schemes in this report focuses primarily on the cssociated DC power schemes. .,

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! A preliminary report was developed on 6-25-86 to provide station management h

!'( with recomendations on problems identified by the review team at that time.

The preliminary reconsnendations and current status of' modification, where applicable, are restated in this report to ensure overlap of effort is t

avoided. These recomendations are listed in the original order of the

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1. PROBLEM Upon loss of ICS power, AFW control is transferred to a backup control scheme that requires pro =::t c::erater acucn to ensure over or under cooling of the RCS is aveiced. -

Solution: Provice AFW control with auto-level control action independent

, of ICS on loss of ICS power.

• Status: A modification is being developed to provice two levels of OTSG

level control following loss of ICS power. The control points -

will be 30" on Startup level (assumes at least 1 RCP running),

or 50% on Operate leve.1 (assumes all RCPs stopped). ' Scheduled for pre startup complet1'on.

2. PROBLEM MFW pump speed control is lost upon loss of ICS power. In addition MFW pump speed is driven to minimum on each reactor ,

trip. Both conditions result in initiation of AFW system.

Solution: Trip both MFW pumps on loss of ICS power to ensure AFW system it activated. -..

Review the current minimum speed setting on the MFW pumps *a ensure the current status meets the original design basis.

Resolve NRC concerns regarding reliable AFW system initiation and the current inadvertent starts when AFW is not required.

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Status: A mocification is being developed to trip botn PJW pumps '

(turbines) following loss of ICS power. This trip will auto reset without recovering the ICS pcwer tc ;c:::it lccal P5W pump operation if necessary.

B&W has been tasked to review the current AFW auto-start against the original design basis and to make reccernendations that should lead to resetting FFW pu:=p minimum speed,

3. PROBLEM ICS response on loss of NNI AC or DC power can result in ICS 9

induced transients. Tripping ICS, following the modifications that provide auto level and pressure control for both OTSGs, will place the plant in 1 known, controllable condition.

Solution: Provide an ICS trip (DC power only) on loss of NNI X or Y or Z DC power and X or Y AC power. Ensure this modification is part of a design package that incl.udes auto level and pressure control for both OTSGs.

Status: A modification 13,.being developed to trip ICS DC power on.. loss of applicable NNI power supplies. This modification is in .

. conjunction with OTSG pressure and level control modifications.

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i 4. PROBLEM Accurate identification of instrumentation by power supply could reduce challenges to the operator on icss of NNI power supplies. The current distribution of power supply loads .

through process control and instrumentation precludes any effective labeling of instruments or selector switches.

Solution: As an interim fix - label all control room instruments driven by NNI and ICS AC or DC power.

As a long tem fix - develop a modification that will place each instrument and process control driven by the NNI system on a single, identifiable 'p~ohr supply with a single, identifiable backup.

Status: Interim labels are being developed. Long term task is not assigned. -

, 5. PROBLEM Reliable SPDS indications are necessary to reduce challenges to the cperators in .detemining*

post-trip conditions. .

Solution: Modify those ' inputs from NNI to SPDS that are effected by loss of NNI DC power. Ensure all SPDS functions for evaluation of post-trip stability are independent of NNI.

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1 Status: A list of SPDS points impacted by less of im LC power nes oeen q, provided to the Nuclear Engineering !!C 2.: p. .

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6. . PROBLEM A number of process monitors necessary to accomplish Casualty Procedures C.15, 16 and 17 (loss of X and/or Y DC oower) are not readily available or in usable form for the operator.

Solution: Provide a dedicated multico4at recceder in the control room with inputs inoependent of UNI. This recorder should continuously monitor the parameters fdentified in CIS, 16 and 17 and the following additional parameters:

. RCP seal supply-flow .

• Letdown flow

• Makeup flow Makeup filter differntial pressure

'* OTSG A and B steam temperatures Status: A list of the necessary parameters has been provided to Nuclear Engineering I&C Group. A modification is being developed to install the necessapy multipoint recorder and a subsequent modification to provide the desired inputs.

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! 7. PROBLEM Direct position indication is not provided'for the TBVs (4)

"O ADVs (2) MFW valves (2) and SUFW valves (2). The operators -

and/or the safety systems may be challenged if, valve positions are not indicated in Control Room.

Solution: Provide actual valve position indication' for TBVs (4), ADvs

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(2), MFW valves (2) and'SUFW valves (2) in Control Room (similar to existing AFW control valve indication).

Status: A modification is being dtveloped to provide the desired valve '

position indication on the HlRI console.

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8. PROBLEM The auxiliary steam pressure control scheme fails the valve to l

50% on loss of ICS DC power, Additionally an electrical group -

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' assigned Deterministic Failure Consequences Analysis have identified an ASC pressure control problem.

Solution: Develop a modification that will ensure the ASC pressure control scheme is independent of ICS or NNI power supply

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failures. This' modification should also address the conceins identified by the DFC electrical group. A copy of this concern ~

was provided to the Nuclear Engineering I&C Group.

Status: 'A' modification is being developed to make the ASC pressure control scheme independent of ICS and NNI power supplies.

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l The following are additional recomendaticr.: nct addrc::ct ir. the Preliminary Report. ^

9. PROBLEM Currently 12 of the 23 NNI inputs to ICS can result in a -

reactor trip on loss of NNI X, Y or I DC power. These inputs are identified in the ICS failure matrix attached to this report. .

In addition to the impact on ICS controls resulting from loss of NNI DC power, the operator is further challenged by loss of -

the associated instrumentation that monitors the ICS inputs (flows, temperatures, level

, etc.).

_ Solution: Pre startup 4 -

1. Modify the 12 NNI inputs to ICS that clearly result in a f

i reactor trip on loss of NNI X, Y or Z DC power. This modification should ensure that either X or Y DC power driven process monitors and controls are operable regardless of the status of X or Y or Z DC power.

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2. Verify tne remaining 11 NNI inputs to ICS do not result in -

a reactor trip on loss of NNI X, Y or Z DC power.

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Long Term .

1. Modify the remaining 11 NNI inputs to ICS to ensure that ,,

either X or Y DC driven process monitcrs ar.d cer.trcis cre operable recardless of the status of X or Y cr Z CC power.

Status: Currently a modification is being developec that will re cive 3 of the NNI inputs to ICS (2 of which can result in a reactor trip) susceptibly to loss of X, Y or I DC power. Therefore, ,

only 10 circuits will require modification before startup. The 3 circuits scheduled for change are: ,

1. Total RC Flow

2. Loop A RC Flow *

3. Loop B RC Flow *

• can lead to a reactor trip on loss of NNI X, Y, or Z DC power 1

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10. PROBLEM The following safeguard systems have flow, level, pressure or temperature instrumentation that receive input from the NNI system:

Emergency Makeup Flow (HPI)

Core Flood Tanks Level Core Flood Tanks Pressure -

• Decay Heat System Flow Decay Heat System Temperatures Nuclear Cooling Service Water Flow l

t j These process monitors are directly imp' acted by various NNI AC or DC power supply failures.

• CU The operator can be challenged when attempting to eva,luate the performance of these safeguard systems following SFAS initiation as a result of, or

subsequent to, loss of NNI AC or DC power.

Solution: Develop a modification that will ensure a valid method of..,

monitoring these parameters is available in the Control Room .

upon loss of any one NNI AC or DC power supply during ECCS operation.

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11. PROBLEM Currently loss of NNI X, Y or Z DC power can result in loss of both primary and secondary process control: anc inc1 cation.

These failures result in loss of:

. Pressurizer level and temperature control and indication

. RCP seal flow and temperature control and indication

, Letdown / Makeup level, flow, pressure and temoerature control and indication i

. OTSG and Steam Header level, pressure temperature control and indication Feedwater flow and ~ temperature control and indication

. Misc indications' Multiple failure modes due to the various power supply failures effects makes definitive operator action for each failure very difficult.

i Current modifications being developed ensure that loss cf ICS 1

or NNI will drive ,tge plant to a known safe condition. The operator will have available, trended infonnation to evaluate -

plant conditions and maneuver the plant to cold shutdown.

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- Fowever, the operator will be cnallengec, as many process tO .

controis w41i be manuai oni , ane men, indications wiii se available by computer presentation only.

l Solution: Modify the NNI process and instrument control schemes to ensure that either X or Y DC'pwer driven controis and indications are

! cperable regardless of the status of any one NNI, DC power l

supply. The final list of process control and indication to be modified should be detemined with full concurrence of Nuclear

, .. Operations. ,

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12. PROBLEM Currently loss.of..NNI X, Y or Z DC power can result in loss of l both primary and seconda'ri alams and system interlocks not

associated with specific process monitors. -

This can lead to a great number of annunciators and interlocks a

having multiple failure modes depending on which power supply -

has failed. Multiple failure modes are:

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• Annunciator failed on HI or LO . ,

• Annunciator failed 0FF _

• Interlock initiated l

• Interlock defeated 6'

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Since process instrumentation would also be defeated at this f[]) time the operator is challenged to determine plant status and ,

avoid unsafe plant conditions.

Solution: Mocify the NNI annunciation and interlock control schemes to ensure that either X or Y DC power driven schemes are operable ,

regardless of the status of any one NNI DC power supply.

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13. PROBLEM A large number of control room instruments and control schemes , . I are not powered or driven by NNI/ICS. Examples of- these are: ,

• Condensate Storage Tank level

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• Hot well makeup / reject control e Borated Water Storage Tank level -

Waste Receiver Tanks A&B level Solution: Conduct a study to identify all process controls and monitors in the Control Room not powered or driven by NNI/ICS.

j Based on the study. covelop suitable documentation to support -

i operator and technician training and control procedures.

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14 PROBLEM A large number of drawir.g errors 6.ere cetected during this h' O review. These were resolved for accuracy as part of the

/ review. Nuclear Operations has assigned an engineer the task of updating all effected NNI/ICS schematics.

• Solution: Nuclear Operations and Nuclear Engineering Systems Engineers should verify satisfactory completion of this schematics update.

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15. PROBLEM ICS drawings h21.01 - 115 through 119 are extracted from B&W Instruction Book #620-0011. These drawings provide the analog '

logic for the ICS. The same instruction book includes the digital logic drawings.necessary to understand the operation of the ICS. These digital logic drawings are not included in the-

- stations controlled drawing system.

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Solution: Incorporate the following B&W digital logic drawings into the site document control system:

L D 554914 ULD, digital logic D 554515 Integrated Master, Logic .

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• D 554916 Feedwater control digital logic.Part I -

+ .D 556492 Feedwater control, digital logic Part II

• D Sfa917 Reactor Control, digital logic l

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Verify that the analog and digital logic diagrams accurately reflect the current ICS configuration.

15. PROBLEM R!S cabinets A&B provide power for the fellcwing ;: recess -

controls and indicators:

OTSG A&B Startup Operate and Wioe Range levels Pressurizer levels HPI flow to each RCP inlet Total seal injection flow (RIA only) ,

. DRS A&B flow Cr7 A&B levels .

Solution: Short Tem Develop procedures and conduct training.on required operator

, actions on loss of RIS A or B. .

Long Term Modify the RIS A & B proce:s and instrument schemes to ensure l

that either RIS. A or B driven process monitors.' controls and.

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interlocks are coerable regardless of the status of RIS A or B -

power. This will require RIS - B also monitor Total Seal Injection Flow.

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'O 17. Paostra arw pump Aas rureine covernor vaive controis are po.eree througn a coninon fuse. F-11, in ICS panel I (N 21.01 - 65/4).

Loss of this fuse will drive both main feed pumps to ":ero -

speed".

Solution: Utilize a spare fuse in ICS cabinet i and split out this source

• of 120 V AC to MFW pump turbine speed control.

ANALYSH '

The following is a list of the suppor.ttng cc:uments and drawings with a brief description of content developed during' the review of loss of NNI/ICS AC and DC power. ..

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~ Attachment 1 NNI/ICS knstrumentation and Process Failure Mode Matrix The matrix. addresses failure modes on loss of:

. NNI X Y and.I DC power .

. NNI X and Y AC power -

+ RIS A&B AC power b

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The matrix is grouped as follows:

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. Pressurizer

. Reactor Coolant System

. Reactor Coolant Pumps

. Makeup and Purification System

. Core Flood Tanks

. Decay Heat Systems

. OTSGs

. Feedwater Systems ,

. ICS Attachment 2 Data sheets for loss of "NNI X DC power - Effects on process controls, instrumentation and ICS.

CO Attachment 3 Data Sheets for loss of NNI Y DC power - Effects on process, controls, instrumentation and ICS.

Attachment 4 Data sheets for loss of NNI Z DC power - Effects on process controls instrumentation and ICS -

Attachment 5 Data sheets for loss of NNI X AC power - Effects on process controls, instrumentation and ICS. -

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Attachment 6 Data sheets for loss"of NNI Y AC power - Effects on process controls, instrumentation and ICS.

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Attachment 7 Data sheets for loss of NNI Z DC power (fused) - Effect: on

( process controls instrumentation and ICS.

Attachment 8 Data sneets for loss of ICS AC power - Effects on process controls instrumentation and ICS.

Attachment 9 Data sheets for loss of RIS A&B AC pcwcr - Effects on process controls, instrumentation and ICS. ,

The following electrical schematics were color coded or yellow . lined to ensure ,

completeness of review and identify the effects on process controls, instrumentation and ICS.

Attachment 10 Loss of NNI X DC power N15.01 57 to 59 61 to 82 N21.01 65 to 85 Attachment 11 Loss of NNI Y DC power N15.01 57 to 59, .

61 *w 82 -

N21.01 ~65.to 85 Attachment 12 Loss of NNI Z DC power N15.01 57 to 59 -

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Attachment 13 Loss of NNI X AC power

_$ .'415.01 57 & 58 1

62 to 82 '

I N21.01 71 to 82 .

Attachment 14 Loss of NNI Y AC power N15.01 59 to 64 N21.01 66 to E2 ,

Attachment 15 Loss of NNI Z (fused) DC power .

N15.01 81 67 & 68 ,

72 & 73 & 78 ~ ~

b Attachment'16 Loss of RIS A AC power .

N15.01 61 69 & 70

, 74 76 79 & 80.,. -

N21.01 78 *w 80 -

E 323 11 & 12

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Attachment 17 Loss of RIS B AC power N15.01 61 69 & 70 .

74. 76 79 & 80 N21.01 78 to 80 E 323 13 l -

Attachment 18 ' Loss of ICS AC power ,

N21.01 65 to 85 i

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