ML17229A272

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LER 97-002-00:on 970221,operation in Excess of Max Rated Thermal Power Occurred Due to Digital Data Processing Sys (Ddps) Calorimetric Error.Verified Acceptable Performance of Ddps Functions & Reviewed Software mods.W/970321 Ltr
ML17229A272
Person / Time
Site: Saint Lucie NextEra Energy icon.png
Issue date: 03/21/1997
From: DIETZ R L, STALL J A
FLORIDA POWER & LIGHT CO.
To:
NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
L-97-081, L-97-81, LER-97-002, LER-97-2, NUDOCS 9703270101
Download: ML17229A272 (10)


Text

CATEGORYREGULAT55f INFORMATION DISTRIBUTIO YSTEM(RIDS)ACCESSION NBR:9703270101 DOC."DATE:

97/03/21NOTARIZED:

NOFACILSO-'33'5St.LuciePlant,Unit1,FloridaPower6Light.Co.AUTH.NAMEAUTHORAFFILIATION DIETZ,R.L.

FloridaPoweraLightCo.STALL,J.A.

FloridaPower&LightCo.RECIP.NAME RECIPIENT AFFILIATION "DOCKET05000335

SUBJECT:

LER97-002-00:on 970221,operation inexcessofmaxRatedThermalPoweroccurredy failuretoimplement effective configuration forDigitalDataProcessing SyscomputerDZSTRZBUTZON CODE:ZE22TCOPZESRECEZUED:LTR

)ENCLtSZZE:TITLE:50.73/50.9 LicenseeEventReport(LER),IncidentRpt,etc.NOTES:RECIPIENT IDCODE/NAME PD2-3PDINTERNAL:

ACRSAEOD/SPD/RRAB NRR/DE/ECGB NRR/DE/EMEB NRR/DRCH/HICB NRR/DRCH/HQMB NRR/DSSA/SPLB RES/DET/EIB EXTERNAL:

LSTLOBBYWARDNOACPOOREPW.NRCPDRCOPIES,LTTRENCL11111111111111111~-1111111RECIPIENT IDCODE/NAME WIENSPL.BILCENTERNNRR/DRCH/HHFB NRR/DRCH/HOLB NRR/DRPM/PECB NRR/DSSA/SRXB RGN2FILE01LITCOBRYCE,JH.NOACQUEENERPDS NUDOCSFULLTXTCOPIESLTTRENCL112211111111111111111111NNOTETOALL"RIDS"RECIPIENTS:

PLEASEHELPUSTOREDUCEWASTE.TOHAVEYOURNAMEORORGANIZATION REMOVEDFROMDISTRIBUTION LISTSORREDUCETHENUMBEROFCOPIESRECEIVEDBYYOUORYOURORGANIZATION, CONTACTTHEDOCUMENTCONTROLDESK(DCD)ONEXTENSION 415-2083FULLTEXTCONVERSION REQUIREDTOTALNUMBEROFCOPIESREQUIRED:

LTTR25ENCL25 aFloridaPower&LightCompany,6501SouthOceanDrive,JensenBeach,FL34957APLMAR2)1997L-97-08110CFR50.73U.S.NuclearRegulatory Commission Attn:DocumentControlDeskWashington, D.C.20555Re:St.LucieUnit1Docket50-335Reportable Event:97-002DateofEvent:February21,1997Operation inExcessofMaximumRatedThermalPowerTheattachedLicenseeEventReportisavoluntary reportsubmitted toprovidenotification ofthesubjectevent.Verytrulyyours,'IJ.A.StallVicePresident St.LuciePlantJAS/RLDAttachment cc:RegionalAdministrator, USNRCRegionIISeniorResidentInspector, USNRC,St.I.uciePlant'703270iOi 97032XPDRADGCK050003358PDRlllgttlllElllPiHillttltl anFPLGroupcompany NRCFORM366(4-as)U.S.NUCLEARREGULATORY COMMISSION LICENSEEEVENTREPORT(LER)(Seereverseforrequirednumberofdigits/characters foreachblock)APPROVEDSYOMSNO.S)50%105EXPIRES05QOISSESTIMATED BURDENPERRESPONSETOCOMPLYWITHTHISMAHDATINFORMATION COILECTIOH REQUEST:50.0HRS.REPORTEDLESSONLEARNEDAREINCORPORATED INTOTHEUCENSINOPROCESSANDSACKTOSE)USIRY.

FORWAIE)COMMBITSREOARDIHO BURDENESTIMATOTHEINFORMATION ANDRECORDSMANAOEMEHT BRANCHIT%F33)UWNUCLEARREOIAATORY COMMISSION, WASHINOTON, DC20555400)

ANDTOTHEPAPERWORK REDUCTION PROJECT131500)04),

OFHCE0MANAOEMENT ANDBUDGET,WASHIHOTON, DC20503.PAcIUTYNAMEl1)TITlEIa)ST.LUCIEUNIT1DocKETNLssBERl2)05000335PAOEIS)1OF5Operation inExcessofMaximumRatedThermalPowerDuetoDigitalDataProcessor Calorimetric ErrorMONTHDAYSEQUENTIAL REV)SIONNUMBERNUMBERMONTHDAYYEARFACIUTYNAMENIADOCKETNUMBER0221OPERATING MODE(9)LEVEL(10)9797-002-0020.2201(b)20.2203(a)(2)(I) 20.2203(a)(2)

(ill)20.2203(e)(2)(iv) 03219720.2203(e)(2)

(v)20.2203(a)(3)(ii) 50.3B(o)(1) 60.3B(c)(2)

FACIUTYNAMENIA50.73(e)(2)

(I)50.73(a)(2)(ill) 50.73(e)(2)(v) 50.73(a)(2)(vli)DOCKETNUMBER50.73(e)(2)(vlii) 73.71OTHERSpecifyInAbstractbeloworInNRCForm3SSANAMER,L.DIETZ,Licensing EngineerTELEPHONE NUMBEROnckdeArseCode)(561)467-7157cAusESYSTEMCOMPONENT MANUFACTURER ToNPRDSCAUSESYSTEMCOMPONENT MANUFACTURER ToNPRDSYES(Ifyes,completeEXPECTEDSUBMISSION DATE):XNoMONTHDAYYEARSUBMISSION DATE(16)ABSTRACT(L(mitto1400spaces,I.e.,approximately 15single-spaced typewritten lines)(16)ThisLERisavoluntary report.OnFebruary21,1997,St.LucieUnit1wasoperating atasteady-state powerlevelof100%RatedThermalPower(RTP)asdetermined fromtheDigitalDataProcessing System(DDPS)display.Whileperforming afeedwaterflowinstrument loopcalibration, maintenance personnel determined thatproperscalingconstants werenotbeingusedforthefeedwaterflowinputsignalstotheDDPS.Thiscondition causedtheDDPScalorimetric calculation ofreactorcorethermalpowertobenon-conservative inthatfacilitysteady-state operation withtheDDPSindicating 100%RTPresultedinactualreactorpowerat100A3%RTP.Plantoperation waslimitedtonotmorethan99%RTP(indicated) whiletheproblemwasthoroughly investigated andcorrected.

OnMarch1,1997,St.LucieUnit1wasreturnedto100%RTP.Thecauseofthiseventwasfailuretoimplement effective configuration controlsfortheDDPScomputersoftware.

Corrective actionsinclude:1)Acceptable performance ofallcriticalDDPSfunctions wasverifiedpriortorestoration offullpoweroperations.

2)Reviewofaccountabilities forsoftwaremodifications andidentification ofprogramimprovements.

3)Development ofverification andvalidation requirements thatchallenge allcriticalattributes forsoftwarechangeswithintheDDPS.4)Development ofcontrolled operating procedures toaddressDDPSoperation.

5)UseoftheSt.LucieTotalEquipment DataBaseorcontrolled procedures toensureconfiguration controlofcriticalDDPSconstants.

6)Modification ofthesoftwarevendorblanketpurchaseordertoclarifythatcompliance withFPLadministrative procedures isrequired.

NRCFORM3SS(4.SS)

NRCFORM388AI4.9SILICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSIO ST.LUCIEUNIT105000335YEARSEQUENTIAL REVISION97-002-002OF5TEXTiifmorespaceisrequired, useadditional copiesofNRCArm3684Il17IOnFebruary21,1997,St.LucieUnit1wasoperating atasteady-state powerlevelof100%RatedThermalPower(RTP)asdetermined fromtheDigitalDataProcessing System(DDPS)[EIIS:IO]

display.UtilityInstrumentation andControl(ILC)personnel wereperforming afeedwaterflowinstrument loopcalibration following maintenance onafeedwaterflowtransmitter

[EIIS:SJ:PDT].

Duringthiscalibration, itwasdiscovered thatscalingconstants forallsixofthefeedwaterflowinputsignalstotheDDPScomputer[EIIS:IO:CPU]

wereincorrect, i.e.,theinputsignalrangeof4-20milliamperes corresponded toaflowventuri[EIIS:SJ:FE]

differential pressurespanofapproximately 0-790inchesofwaterratherthanthecorrectspanof0-800inchesofwater.SincetheDDPSusesthefeedwaterflowparameter incalorimetric calculations ofreactor[EIIS:RCT]

corethermalpower,thisdiscrepancy wasnon-conservative inthatscalingconstants corresponding tolessthanthefullrangeofflowventuridifferential pressures resultinacalculated valueofpowerthatislessthantheactualreactoroutput.Controlroomoperators werenotifiedbyILCpersonnel thatthereactorwasoperating atacorethermalpowerlevelapproximately 0.6%RTPgreaterthanthevaluedisplayed ontheDDPS,andactionwaspromptlyinitiated toreducepower.At17:55ESTonFebruary21,1997,St.LucieUnit1wasstabilized ataconservative valueof99%RTP(indicated).

Theunitwasreturnedto100%RTPat05:45ESTonMarch1,1997.InJune,1994,feedwaterflowscalingconstants wererevisedinaccordance withapprovedplantprocedures.

Thesescalingconstants wereproperlyinstalled intotheoperating DDPSsoftware, butwerenotupdatedinthecontrolroomDDPSdatareference manual.In1996,thesoftwarewasmodifiedbythevendorusingthevendor'sversionofthesourcecodetoaccommodate installation ofanewcoreperformance monitorthatinterfaces withtheDDPS.Whenthismodification wasloadedintotheDDPScomputerduringthe1996refueling outage,theproperscalingconstants wereoverwritten andreplacedwiththepre-1994valuesbasedonthecontrolroomDDPSdatareference manual.Thiscondition wasnotdiscovered untiltheinstrument loopcalibration wasperformed onFebruary21,1997.Thecauseofthiseventwasfailuretoimplement effective configuration controlsfortheDDPScomputersoftware.

lnJune1994,achangetothespan/static shiftadjustment foreachofthesixDDPSfeedwaterflowtransmitters wasimplemented inaccordance withanapprovedplantworkorder.Tobecompatible withthespanadjustments, theexistingfeedwaterflowscalingconstants corresponding toaspanof0-790.6inchesofwater'differential pressurewererevisedtocorrespond toaspanof0-800inchesofwaterdifferential pressure.

Thenewscalingconstants wereloadedintothecorrectDDPSoperating softwarelocations, butwerenotrecordedinthecontrolroomDDPSdatareference manualwhichismaintained attheDDPSconsole.NRCFORMmAIi-95I

NRCFORM386AI4.96)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREOULATORY COMMISSIO ST.LUCIEUNIT105000335YEARSEQUENTIAL REVISION97-002-003OF5TEXT/ifmorespecsisreriuired, useedditionel copiesofNRC.cform36EAII17)TheDDPSsoftwareisconsidered qualityrelated.Atthetimethe1994revisionwasmadetothefeedwaterflowscalingconstants, Ql2-PR/PSL-3, Revision0,ControlofComputerSoftware, providedgenericadministrative controlsforcomputersoftwareinwhichtheoutputisusedforsafetyrelatedandqualityrelatedpurposes.

Significant revisions tostrengthen thisprocedure havebeenmadesince1994.Duringtherefueling outageofApril-July,1996,anon-linecore'performance monitoring systemwhichinterfaces withtheDDPSwasinstalled inaccordance withanapprovedPlantChange/Modification (PC/M).TheDDPSsoftwarechangesneededtoaccommodate thisnewinstallation weredeveloped bythevendorusingthevendor'sversionofthesourcecode(whichdidnotcontainthe1994revisedscalingconstants).

UponloadingthemodifiedsoftwareintotheDDPScomputer, thecorrectfeedwaterflowconstants wereoverwritten withthosecorresponding toarangeof0-790.6inchesofwaterdifferential pressure.

Administrative Procedure (AP)4000060,Maintenance Departmental ControlofComputerSoftware, wasimplemented February26,1996,toprovidethemethodology bywhichthemaintenance department andsupportgroupscontroltheprocurement, development, andrevisionofsoftwaretocomplywithQl2-PR/PSL-3.

Thevalidation andverification (V&V)methodthatwasusedtoconfirmtheDDPSpropersoftwareconfiguration following modifications toaccommodate the1996PC/Mwasselectedfromthisprocedure, butdidnotV&Votherfunctions ofthesoftware, suchasthecalorimetric calculation, thatwerenotrelatedtothemodification.

Duringpostmodification testing(PMT)forthe1996PC/M,thecontrolroomcopyoftheDDPSdatareference manualwasusedtoperformaverification ofeachDDPSinputconstant.

However,thismanualisnotacontrolled documentandhadnotbeenupdatedtoreflectthe1994revisiontothefeedwaterflowscalingconstants.

Thisprevented discovery oftheproblematthattime,i.e.,thevaluesusedtoverifythefeedwaterflowscalingconstants werethesamepre-1994valuesasthoseresidinginthesoftwarethathadbeenloadedintotheDDPScomputerfromthevendorsourcecode,Thefeedwaterflowscalingconstanterrorwasdetermined tobe.non-conservative by0.6348RTP.Twoadditional discrepancies, unrelated tothe1996modification, werealsodiscovered inthecalorimetric calibration andweredetermined toresultinacombinedconservative errorof0.2%RTP.Therefore, thenetcalorimetric errorwas0.43%non-conservative.

Anoperability assessment wasperformed whichdetermined thatthefeedwaterflowscalingdiscrepancy combinedwiththecalorimetric measurement unertaintywaslessthantherequiredoverallcalorimetric accuracyrequirement of2%atmaximumratedthermalpower.Inaddition, reactorprotection, corephysics,andreactorfuelparameters impactedbythecalorimetric errorwereevaluated toensurethatassumptions madeintheplantsafetyanalysisprovidedsufficient margintoboundthisevent.Thisevaluation concluded thattheexistingplantsafetyanalysisremainsvalid.Therefore, thehealthandsafetyofthepublicwerenotadi>>elyaffectedbythisevent.NRCFoRM388A(4-96I NRCFORM3SBAI4-96)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSIST.LUCIEUNIT105000335YEARSEQUENTIAL REVISION97-002-004OF5TEXT(ifmorespeceisrequired, useedditionel copiesofIVRCForm368AiI17)Facilityoperation waslimitedtoaconservative valueof99%RTPuntiltheproblemwasthoroughly investigated andcorrected.

Primarysystemmanualcalorimetric calculations wereperformed toverifyreactorpowerremainedbelow100%RTP.2)Thecorrectfeedwaterflowscalingconstants wereenteredintoboththeon-lineandtheback-upDDPScomputers, andothercalorimetric constants wereverifiedtobecorrectusinginformation frotheplantTotalEquipment DataBase(TEDB).Theincreaseincalculated calorimetric powershownontheDDPSdisplaywasverifiedtobeaspredicted.

Aprimarysystemmanualcalorimetric calculation wasperformed andresultswerewithin0.2%ofDDPSindicated power.3)Thecorrectfeedwaterflowscalingconstants weredocumented, andmaster/backup copiesoftheupgradedsystemwerefiledinaccordance withanapprovedSt..LuciePlantSoftwareConfiguration/Change Control,ComputerSoftwareChangeRequest(Administrative Procedure 4000060,Revision2).Acceptable performance ofothercriticalDDPSfunctions wasverifiedtoensurethatotherinadvertent softwarechangeshadnotbeenmade,andsurveillances wereperformed forotherplantsystemswhosecalibrations canbeinfluenced byDDPScalculated calorimetric powertoensurethatthesesystemcalibrations hadnotbeencompromised.

5)I&Cperformed athreepointcalibration ofallDDPScalorimetric inputstoverifytheproperscalingconstants andinputcircuitoperation.

Minordiscrepancies wereidentified inthefeedwaterResistance Temperature DetectorandReactorCoolantPumpKWscalingcurvesthatwerenotrelatedtotheeventreportedinthisLER.Engineering determined thatthesediscrepancies accounted foracombinedconservative errorof0.2%.FPLwillrevisethesoftwaretocorrecttheseerrorsintheSt.LucieUnit1DDPS.Thescalingcurvesforthesecomponents werealsoverifiedintheSt.LucieUnit2DDPStoensurethatsimilardiscrepancies didnotexist.6)Toensureadequatepostmodification testingisperformed, FPLwillreviewsoftwaremodification accountabilities andidentifyprogramimprovements tobemade.7)FPLwilldevelopgenericV&Vrequirements tochallenge allcriticalattributes withinbothSt.LucieUnit1andUnit2DDPSforallsoftwarechanges.8)Controlled operating procedures willbedeveloped toaddressbothSt.LucieUnit1andUnit2DDPSoperation andidentifyspecificpointidentification andlocations.

9)FPLwillensureconfiguration controlforallcriticalSt.LucieUnit1andUnit2DDPSconstants byenteringthemintotheTEDBorensuringtheyaredocumented inacontrolled procedure.

10)FPL'sblanketpurchaseorderwiththesoftwarerendorhasbeenmodifiedtoclarifythatdevelopment ofnewsoftwareandupgrading/changing existingsoftwareshallbeperFPL'sAdministrative Procedure AP-4000060.

NACFORM388AI4-96I NRCFORIN388AI4-95),LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUcLEARREGULATORY colNMISSIO ST.LUCIEUNIT1YEARSEQUENTIAL REVISION0500033597-002-005OF5TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366AIl17INoneLER335/86-005, St.LucieUnit1,Technical Specification Deviation DuetoPersonnel Error,07/21/86.

LER389/92-008, St.LucieUnit2,DigitalDataProcessSystemCalorimetric ErrorduetoInstrument Calibration Error,Revision1,03/31/93.

NACFoAM388AI4-96)

I