ML20204E850

Plant,Four Yr Simulator Test Rept for Period Ending 990321

ML20204E850
Person / Time
Site:	Sequoyah
Issue date:	03/21/1999
From:	TENNESSEE VALLEY AUTHORITY
To:
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ML20204E831	List: ML20204E825 ML20204E850
References
NUDOCS 9903250151
Download: ML20204E850 (10)

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SEQUOYAH NUCLEAR PLANT Four Year Simulator Test Report for Period Ending March 21,1999 I

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Report Prepared By: b O,

[Sirdulator Cenification Engineer

/ l[N Report Approved By: / *!

dimulator Sen6es Manager  !

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Sequoyah Nuclear Plant Four Year Simulator Test Report for Period Ending March 21,1999 Table of Contents 1

I Tonic Page l I. INTRODUCTION I II. GENERAL DISCUSSION-- - - ---~~~~ I III. DESCRIPTION OF COMPLETED TESTS - ~~-- - ~ ~~~~~~~.2 A. Steady State Tests --~~~~~~ ~~ - -~~~~ -- ~~ ~~~ -.2 B. D ri ft Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. Transient Tests ------~~~-~~ ~ 3 i

D. Pro c ed ure Tes ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E. Malfunction Tests- 4 F. Real Time Tests ~~~ ~~~~ - - - ~~~---- ~ ~~..... .. 6 G. Simulator Fidelity ~ ~ ~ ~ ~ ~ ~~-~~ ~ --. .. . .. . ... ....... ...... .......... . . 6 H. Simulator Limitations ~~~~ -- ~~........ ............ ............ .... ........ 6 I. S imulator Exceptions . .... .. ... . . . . . . .. . . . . .. . . .. . . . . . . .. . .. .. . . .. . ... . . . . . . . . . . .. . . . ... . . . . . 7 IV. STATUS OF UNCORRECTED TEST PERFORMANCE DEFICIENCIES l RE PORTED IN 1995 -----~~ ~ ~~ - - ~ ~ -.............. ..... . .. 7 V. UNCORRECTED TEST PERFORMANCE DEFICIENCIES AND CORRECTION SCHEDULE-~~~~~ 8 i

i VI. DESCRIPTION OF TEST DIFFERENCES FOR THE NEXT FOUR YEAR TEST P ERI O D - ~ ~ - --------- ~ ~ - --- ~ ~ ~ ~ -- ~ ~ ... . . . . . . . . . . 8 -

VII. SCHEDULE FOR TESTING DURING THE NEXT FOUR YEAR TEST PE RI OD ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ - -- ~ ~ ~ ~ ---~ ~ 8 List of Tables  !

l Table 1 Critical and Non-Critical Test Parameters ~~ ~ ~~~ ------- 2 Table 2 Transient Test L ist . . .. . . . . . . . . . . . . . ..... . .. . . . . . . .. . . . . . . . . . . . .. . . .. . . . . .. . . . .. . . . . . . .. .. . .

Table 3 Procedure Test List 4 Table 4 Malfunction Test List - ~~ ~~ 4 l Table 5 Limitations List - - . .. . .. . .. . . . . . .. .. . . . ... .. . .. . . .. . . .. . .. . . . . . . . . .. . . . . . . .. . . .. . . . . . . . . . . . .

l Table 6 Open Exception Report List -- ~~~........ .................... .. ..... ...... 7 Schedule for the Correction of Test Deficiencies 8 Table 7 Table 8 - Schedule for Testing During the Next Four Year Test Period............ .. 8 Pagei C

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• Sequoyah Nuclear Plant Four Year Simulator Test Report for Period Ending March 21,1999 I. ' INTRODUCTION The submittal date of the initial certification of the Sequoyah simulator was March 21,1991. The simulator certification process determines compliance on a four year interval with the requirements of ANSI-3.5-1985, Nuclear Power Plant Simulators for Use in Operator Training. This report outlines the test methods used, identifies any uncorrected test deficiencies, and includes a schedule for their

- correction. This report must be submitted to the NRC on the anniversary of certification, in accordance with 10 CFR 55.45 (b)(5)(ii).

Simulator test schedules were provided in the four year report submitted in March 1995. The tests were completed as outlined in those schedules.

I' II. GENERAL DISCUSSION The Sequoyah simulator was first used for operator training in 1979 -- the original vendor was S3 Technologies (Singer-Link). It is used to license operators on both Unit I and Unit 2, with Sequoyah Unit I as the design reference plant. Since the last report submitted in 1995, the simulator has been used nearly continuously for l various training needs at Sequoyah. . During this testing period it has been maintained as required. Modifications and tuning adjustments were completed on a regular basis to maintain simulator configuration as close as practical to Unit 1.

-The Sequoyah simulator uses a computer system that last received an upgrade in 1995. The main simulator computer uses two Mercury i860 processors. The simulator I/O system was completely upgraded and replaced in a phased-approach over a five year period, with the project completing in 1998. Sun workstations provide the instructor station and model development interface. One major plant modification that was installed two years ago involved the replacement and modification of simulator furniture, computer monitors, computers, computer ,

l peripherals, and various printers in the Main Control Room horseshoe area to replicate the new Integrated Computer System.

During the past four years, work on the simulator included tuning models to match plant data, improving model performance, installing new training malfunctions, i

and implementing plant design changes. Problem Reports (prs) and Design Change Requests (DCRs) were processed during this period, as follows. i Work Item Number at Start

• Opened Closed Number at End*

Problem Reports 60 690 730 20 l Design Change Requests 36 136 150 22 l

• NOTE: Each of the prs and DCRs t - ig at the start were completed by the end of the i four year test period. 'The N, aber at End were documented . March 1,1999. l Page 1 of 8 j

Sequoyah Nuclear Plant Four Year Simulator Test Report for Period Ending March 21,1999 111l DESCRIPTION OF COMPLETED TESTS This section summarizes the tests completed on the simulator over the past four years. Detailed test documentation is maintained by the Simulator Services Froup at the Sequoyah Training Center for review, in accordance with the requirements of 10 CFR 55.45 (b)(5)(iii). The uncorrected deficiencies are described in Section V, Uncorrected Test Performance Deficiencies and Correction Schedule.

A. Steady State Tests Steady State Tests were performed annually. Plant critical and non-critical test parameters (refer to Table 1) were compared to the equivalent simulator values at each of three power levels. The error was calculated based on 12% of span for critical and i 10% of span for non-critical parameters. A total of six deficiencies were captured in prs or DCRs in the last four years: all of these were resolved, 1

TABLE 1 l CRITICAL TEST PARAMETERS NON-CRITICAL TEST PARAMETERS I Generator Gross MW Generator Voltage Reactor Thermal Power Calculated Generator MVARs Intermediate Range Channel RCS Loop Average Temperatures Power Range Channels RCS Loop Over-Power Delta-Temperatures Control Bank D Rod Position RCS Loop Over-Temp Delta-Temperatures RCS Loop Flows Reactor Vessel Wide Range Level RCS Hot Leg Loop Wide Range Temperatures Reactor Vessel Narrow Range Level RCS Cold Leg Loop Wide Range Temperatures Reactor VesselPlenum Level RCS Auctioneered High Average Temperature Pressurizer Relief Tank Level RCS Reference Temperature Pressurizer Relief Tank Press RCS Loop Delta-Temperatures Pressurizer Relief Tank Temp Charging Pump Discharge Header Pressure Refueling Water Storage Tank Level Pressurizer Level Accumulator Tank Levels Pressurizer Pressure Accumulator Tank Pressures Containment Pressure Charging Header Flow Steam Generator Narrow Range Levels Letdown Flow Steam Generator Feed Flows Steam Generator Wide Range Levels Steam Generator Steam Flows Feedwater Header Pressure Steam Generator Steam Pressures 125VDC Vital Battery Board Voltages Steam Line Header Pressure 250VDC Batterv Board Voltage

1. 1 Feedwater Heaters Outlet Header Pressure 480V Shutdown Board Voltages 6.9 kV Shutdown Board Voltages 500 kV Bus Voltage CCS Heat Exchanger Inlet Pressure ERCW Supply Header Flows Page 2 of 8

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Sequoyah Nuclear Plant ,

Four Year Simulator Test Report for Period Ending March 21,1999 1 B. Drift Tests

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Drift Tests were performed annually. The simulator was reset to 100 percent power and data was collected for an hour for each critical parameter at a rate of two samples per second. Plots were made with this data to i check for stability. A parameter would fail the test ifit drifted beyond 2% of the initial value. No test deficiencies occurred.

l C. Transient Tests The 10 Transient Tests were performed annually (refer to Table 2). Data l was collected for required parameters at a rate of two samples per second.  !

Each year the test results were plotted and compared with responses from {

the prior year and with initial certification data. Additionally, a Transient j Reviev Committee consisting of engineers, instructors and operators evaluated each Transient Test in January 1999 for an independent evaluation. Each of the 10 transients were given this additional review. A i total of five deficiencies were captured in prs or DCRs in the last four years: two prs remain to be completed.

I TABLE 2 )

TRANSIENT TEST LIST

1. Mar.ual Reactor Trip

2. Simultaneous Trip of All FW Pur:r:.

3. Simultaneous Closure of All MSIVs

4. Simultaneous Trip of All RCPs

5. Trip of Any Single RCP -

6. Main Turbine Trip at Max Power that Does Not Result in Reactor Trip (<P-9)

7. Maximum Power Ramp (100% To 75% Then Back Up To 100%)

8. Maximum Size Reactor Coolant System Rupture Combined wit h Loss of All Offsite Power

9. Maximum Size Un Isolable Main Steam Line Rupture -

10. Slow Primary System Depressurization to Saturated Condition Using Pressurizer Relief or Safety Valve Stuck Open with No High Head Injection D. Procedure Tests To distribute the work load between each testing year, approximately 25 percent of the procedure tests were performed each year. At the completion of the four year test cycle, each of the procedure tests had been completed. Table 3 provides a summary of the tests performed. Each test used the latest revision of Unit I controlled procedures. A total of 36 deficiencies were captured in prs or DCRs in the last four years: three DCRs remain to be completed. i l

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Sequoyah Nuclear P! ant Four Year Simulator Test Report for Period Ending March 21,1999 TABLE 3 _

PROCED ' E TEST LIST l

Annual l Test Period Ending Procedure Description )

1996 General Operating Procedures: Plant Start Up from Cold Iron to 100 Percent Power 1997 General Operating Procedures: Plant Shutdown from 100 Percent Power to Cold Iron {

1998 Emergency Operating Procedures (inciades Functional Restoration Guidelines and l Emergency Contingency Actions) 1999 Abnormal Operating Procedures and Emergency Abnormal Procedures NOTE: The schedule above shows which set of procedures were performed during a particular test year.

Detailed procedure numbers are not used because they may change. The test period ends on March 21 of each test year.

E. Malfunction Tests )

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To distribute work load h each testing year, approximately 25 percent of required malfunctions v, te tested annually (refer to Table 4). At the completion of the four year test cycle, each of the required malfunctions had been tested. After inserting each malfunction, simulator response was compared to the Malfunction Cause and Effects document, to plant procedures, and to available actual plant data. Additionally, a check was j made to ensure that an appropriate Initial Condition existed, that the j simulator could be operated io a steady state condition, that operators l would take the same actions in the reference plaat, that the variable rate features (if any) could be manipulated, and whether or not the malfunction j could be removed. A total of 37 deficiencies were captured in prs or i DCRs in the last four years: all of these were resolved.

I TABLE 4 I MALFUNCTION TEST LIST A"""*I #SI

. Item Malfunction Malfunction ANSI-3.5 Number Number Description Section 1996 I CV09 VCT Leyel Transmitter Fails High 3.1.2(18) 2 TH05 Steam s nerator Tube Leak 3.1.2(l a) 3 CV04 Letdown Line Break inside Auxiliary Building 3.1.2(l b) 4 TH03 Small Break Loss of Coolant Accident 3.1.2(Ic) 5 TH04 Failure of Pressurizer Safety Vah e 3.1.2(1d) 6 RDl3 Stuck Rod 3.1.2(12) l 7 1A02 Loss of Non-Essential Control Air 3.1.2(2) 8 ED01 Total Loss of Offsite Power 3.1.2(3) 9 ED06 Loss of 6.9kV Shutdown Board 3.1.2(3) 10 ED08 Loss of 480 VAC Shutdown Board 3.1.2(3)

Note: The test peric.d ends on March 21 of each test year.

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l Sequoyah Nuclear Plant I Four Year Simulator Test Report for Period Ending March 21,1999

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TABLE 4 (Continued)

MALFUNCTION TEST LIST est

^"""".1 Item Malfunction Malfunction ANSI-3.5

]; Number Number Description Section 1997 1 EDl5 Loss 'of 250 VDC Battery Board 3.1.2(3) i 2 RC01 Reactor Coolant Pump Locked Rotor 3.1.2(4) 3 RDOS Rod Misalignment 3.1.2(12) 4 RWO2 Raw Cooling Water Pump Trip 3.1.2(6) 5 RWO7 Loss of Cooling to Main Feed Pump Oil Coolers 3.1.2(6) 6 RH04 Residual Heat Removal Loop Suction Line Blockage 3.1.2(7) 7 RP01 Reactor Trip Signa! Failure 3.1.2(24) 8 CC04 Component Cooling Pipe Break inside Containment 3.1.2(8) 9 CN02 Condensate Booster Pump Trip 3.1.2(9) 10 MS01 Main Steam Line Break inside Containment 3.1.2(20) 11 FWO5 Loss of All Feedwater: Trip of Turbine MFWP 3.1.2(10)

FWO7 Loss of All Feedwater: Trip of AFWP 3.1.2(10) 1998 1 T1101 Hot Leg Loss of Coolant Accident 3.1.2( Ic) 2 Tt 02 Main Turbine High Vibration 3.1.2(15) 3 EG01 Main Generator Trip 3.1.2(16) 4 ED10 Loss of 120 VAC Inverter 3.1.2(3,11) l 5 RX18 Failure of T-average Control Signal 3.1.2(17)  !

6 RX07 Pressurizer Pressure Transmitter Failed High 3.1.2(18) 7 RH01 Rer! dual Heat Removal Pump Trip 3.1.2(7) 8 RP95 False Auto Reactor Trip Signal 3.1.2(19) 9 MSu2 Main Steam Line Break Outside Containment 3.1.2(20) 10 FW23 Main Feedwater Line Break Inside Containment 3.1.2(20) 11 RD07 Dropped Rod 3.1.2(12) 1999 1 ED12 Loss of 125 VDC Vital Bus 3.1.2(3) 2 N107 Power Range Channel Output Signal Failure 3.1.2(21) 3 HD12 #1 Feedwater Heater Level Control Failed Low 3.1.2(22) 4 CN09 Loss of Vacuum 3.1.2(5) 5 CV15 Charging Flow Control Problem: Pressurizer Level 3.1.2(22)

Swing 6 RP02 Auto Safety injection Initiation Signal Failure 3.1.2(23) 7 IA03 Loss of Essential Control Air 3.1.2(2) 8 RD08 Rodt Fail to Move on Demand 3.1.2(13) 9 THR02 Fuel Cladding Failure 3.1.2(14) 10 FW20 Main Feedwater Line Break Outside Containment 3.1.2(20) 1I NIO4 Intermediate Range Channel Failure 3.1.2(21) 12 CV01 Charging Pumns Trip 3.1.2( l 8) 13 CV16 Failure of Letdown Relief Valve 3.1.2(22) l 14 RC05 Failure of Pressurizer Power Operated Relief Valve 3.1.2(I d) 15 EG02 Loss of Emergency Diesel Generators 3.1.2(3) 16 CN23 Loss of Condenser Level Control (Hotwell Dumpback) 3.1.2(5)

CN29 Loss of Condenser Level Control (Hotwell Makeup) 3.1.2(5)

! Note: The test period ends on March 21 of each test year.

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l Sequoyah Nuclear Plant Four Year Simulator Test Report for Period Ending March 21,1999 F. Real Time Tests Thrce types of Real Time Tests were performed annually:

1. Each Transient Test was checked by a stop watch against the computer run time clock.

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2. The simulator uses a real time executive test, which nms continually and monitors the execution of all simulation models. If a portion of a calculation does not finish in time, the simulator will automatically halt. A check confirmed that the simulator did not halt during any Transient Test.

3. For testing purposes, the simulator was forced to slip a timing frame j to ensure that the simulator would halt.

No Real Time Test deficiencies were found.

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G. Simulator Fidelity As modifications are being initiated in the plant, design c'iange packages are reviewed by the simulator statTfor applicability. Additionally, photographs j are made of the plant Main Control Room panels for comparison with the simulator. Items that were identified as having training impact were incorporated into the simulator under the DCR process. Plant changes are required to be compiled at least annually, and appropriate simulator modifications are required to be made within the following year. The required modifications were implementei within these time limits.

H. Simulator Limitations The Sequoyah simulator imposes four Limitations (refer to Table 6). It is possible to create events on the simulator which progress beyond plant design limits. To avoid negative training, which could result from simulator operation during such events, the occurrence of an event on the simulator that progresses beyond the plant design limits causes the simulator to automatically halt.

TABLE 5 LIMITATIONS LIST

1. Containment pressure exceeds the design limit (15psig).

2. Fuel clad temperature exceeds the clad melt point (1533 degrees K).

3. Turbine extraction lines flood (any FW Heater full of uter, with water in extraction line).

4. Turbine shaft seizes (bearing oil temperature >235 degrees F, and turbine speed <0.1 RPM).

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l Sequoyah Nuclear Plant L Four Year Simulator Test Report for Period Ending March 21,1999 L Simulator Exceptions Significant differences in simulator fidelity, other than those addressed by open prs or DCRs, are tracked as Exception Reports (refer to Table 6 for the current list). Each have been evaluated to have no negative impact on training.

TABLE 6 OPEN EXCEPTION REPORT LIST X P on O "

l Exception Description D

2 3/4/91 The ceiling and lighting do not match the plant Main Control Room; the plant ceilin;; diffuser grid is suspended ~12 inches above the panels; normal plant lighting is AC fluorescent lighting at ove the diffuser grid; and, emergency I plant DC lighting is either wall mounted or suspended below the diffuser grid The simulator is in a two story room with recessed Mercury vapor lighting.

The second floor walls are lined on two sides with floor-to-ceiling glass windows for viewing from the second floor, fitted with adjustable shades.

l The simulator can replicate neither the loss of AC lighting nor the use of emergency DC lighting.

3 3/4/91 Panel M-7 is not simulated. In the plant, this penel contains the preferred and instrument power distribution breakers and transfer switches (remote functions are available).

4 3/4/91 Panel M-8 is nc,t fully simulated. The rod coil disconnect switches are simulated. but turbine supervisory power drawers are not. I 6 3/4/91 Panels M 21 and M-22 are not simulated. Plant panels contain the annunciator logic and SSPS demultiplexer cabinets.

8 3/4/95 Panel M-28A is not fully simulated for Unit 2 EGTS controls, and it is not located the same distance from the horseshoe as in the plant.

9 3/4/91 Electrical Control Board (switchyard control) is only partially simulated -- th<

side to side spacing of breaker bays has been collapsed to preserve floor spac< .

12 7/21/92 Back panel M-31 is par,ially simulated -- a radiation monitor controller and two recorders are not simulated due to little use and high cost to replicate.

14- 11/10/94 The simulator cannot be used for training on Unit 2 procedures.

• Note: For brevity, thmix (6) closed Exceptions are not listed.

IV. Status of Uncorrected Test Performance Deficiencies Reported in 1995 Five open test deficiencies were documented in the four year report submitted in 1995. All five items were completed prior to their scheduled date.

V. Uncorrected Test Performance Deficiencies and Correction Schedule Five open test deficiencies exist at the start of the next four year testing period.

They are planned for correction as shown in Table 7.

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l Sequoyah Nuclear Plant  ;

l Four Year Simulator Test Report for Period Ending March 21,1999 l .

TABLE 7 SCllEDULE FOR Tl!E CORRECTION OF TEST DEFICIENCIES Test Deficiency l Description of Deficiency Scheduled Date Transient PR-2661 RCS loop delta-temperature is to . .aw during 7/1/99 Natural Circulation.

PR-2802 S/G Safety valves incorrectly open on a loss of 7/1/99 steam dumps.

Procedure DCR-750 Add the Unit 2 Yokogowa EGTS controllers to 7/1/99 panel M-28.

DCR-790 Add remote functions for stripping individual 5/28/99 breaker loads from vital battery boards.

DCR-815 Simulate Unit 2 Emergency Shutdown buses 5/28/99 supplying Unit 16.9 kV Shutdown boards.

VI. DESCRIPTION OF TEST DIFFERENCES FOR THE NEXT FOUR YEAR TEST PERIOD During the next four year test period, each simulator test is planned to be performed in a manner similar to that of the previous period; no changes are anticipated in critical and ncn-critical test parameters.

VII. SCIIEDULE FOR TESTING DURING THE NEXT FOUR YEAR TEST PERIOD Table 8 lists planned test starting dates for the next simulator reporting cycle. The next anniversary of the Four Year Simulator Test Report is March 21,2003.

TABLE 8 SCHEDULE FOR TESTING DURING THE NEXT FOUR YEAR TEST PERIOD Planned Planned Planned Planned Stan Year 1 Stan Year 2 Start Year 3 Start Year 4 Test Type (Test Period (Test Period (Test Period (Test Period Ending Ending Ending Ending 3/21/2000) 3/21/200I) 3/2I/2002) 3/21/2003)

Procedure * (25% annually) 9/1/1999 9/1/2000 9/1/2001 9/1/2002 Transient /Real Time (100% annually) 10/1/1999 10/1/2000 10/1/2001 10/1/2002 Malfunction ** (25% annually) 11/1/1999 11/1/2000 11/1/2001 11/1/2002 Steady State (100% annually) 12/1/1999 12/1/2000 12/1/2001 12/1/2002 Note:

• Procedure tests will be conducted each test year in the pattern shown in Table 3.

• • Malfunction tests will be conducted each test year in the pattern shown in Table 4.

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