http://fiatech.org/images/stories/events/techconference/2009/iPLMClosingtheLoop by FIATECH

Ne N New Nuclear clear Plant Configuration Management and Information Interoperability

Russell Adams Nuclear Development

ÂŠ 2009 Dominion

The Who

ÂŠ 2009 Dominion

The Vision New plants will be designed differently than in the past. Virtual Plant software will be used extensively. As a result, these plants will be delivered with Virtual Plant models that are comprehensive, detailed and integrated with plant design, design operations and maintenance databases and documents/records.

ÂŠ 2009 Dominion

The Must Nuclear Configuration Management g

Design Basis

Design Requirements “What needs to be there”

Facility Plant Configuration Conform Docs Information “What we say is there” Work Processes must assure that:

Physical Configuration Physical Plant “What What is actually there”

The Case On October 9 9, 1996 the Nuclear Regulatory Commission issued a letter to every Nuclear Utility in the United States entitled, "Request For Information Pursuant To 10 CFR 50 54 ( F ) Regarding 50.54 R di Adequacy Ad And A d Availability A il bilit Of Design Bases Information“ CFR = Code of Federal Regulations = The Law

The Request • Description of engineering design and configuration control processes • Rationale for concluding that design bases requirements are translated into operating operating, maintenance maintenance, and testing procedures • Rationale for concluding that system, structure, and component configuration and performance are consistent with the design bases • Processes for identification of problems and implementation off corrective ti actions ti • The overall effectiveness of current processes and programs in concluding that the configuration of your plant(s) is consistent i t t with ith the th design d i bases b © 2009 Dominion

The Why Nuclear Configuration Management g

Design Basis

Design Requirements “What needs to be there” Pre-1997 Millstone Nuclear Plant Inaccurate or Missing

Facility Plant Configuration Conform Docs Information “What we say is there” must assure that: Work Processes did not assure that:

Physical Configuration Physical Plant “What What is actually there”

The Impact Millstone Nuclear Plant •

Unit 1 shut down permanently

•

Unit 2 and 3 were shut down over two and a half years

•

Billions of dollars in lost revenues and recovery costs

Industry •

DC Cook C k Nuclear N l Plants Pl t shutdown h td ffor over ttwo years

•

Clinton Nuclear Plant shutdown for over two years

•

Dominion response to the NRC Letter cost an estimated $50$50 million

Configuration Management improved in the industry 8

The Challenge Nuclear Configuration Management g

Knowledge Workers EDB

Paper-based Quality Assurance Process

Automation Systems

Conform Challenge

Plant Documentation

The Truth

ÂŠ 2009 Dominion

The Food-For-Thought “If y you always y do what y you have always y done,, y you will always be where you have always been” unknown

“We can’t solve problems by using the same kind of thinking we used when we created them” Albert Einstein

“Think outside the Paper” Russell Adams

“Other Players “Oth Pl go to t where h the th puck k is i I go where the puck is going to be” Wayne y Gretzky y

The Need A modern automated, integrated and interoperable Configuration Management Program must be established to â&#x20AC;˘ Maintain consistenc consistency between bet een the design requirements, physical configuration and facility configuration information â&#x20AC;˘ Ensure the ability to document and maintain compliance with the license basis Needs to be significantly different than Configuration Management programs currently used by operating plants

ÂŠ 2009 Dominion

The Action Industry Initiative : Achieving New Nuclear Virtual Plant Configuration Management g • Standard Configuration Management Reference Model and Implementing Guideline • New Nuclear Plant Information Handover Guide • New Nuclear Plant XML Equipment Schemas

The Journey to where the puck is going to be Achieving New Nuclear Virtual Plant Configuration Management EPRI Advanced Nuclear Technology gy Program g • Technical Advisory Groups • • • • • •

Owner Operators R Reactor V Vendors d EPC Companies Technology Developers Industry Consortium Government

Thank You

Russell Adams N l Nuclear Development D l t Dominion 804 273 2744 804.273.2744 Russell.Adams@dom.com

ÂŠ 2009 Dominion

Advanced Nuclear Technology (ANT) Program Achieving New Nuclear Virtual Plant Configuration Management

Ken Barry Senior Project Manager

EPRI Portfolio Spans the Entire Electricity Sector

Generation

Advanced Coal Plants, Carbon Capture and Storage

Combustion Turbines

Environmental Controls

Generation Planning

Major Component Reliability

Operations and Maintenance

Renewables

Power Delivery & Utilization

Nuclear Power

Environment

Material Degradation/Aging

Distribution

Air Quality

Fuel Reliability

Energy Utilization

Global Climate Change

High-Level Waste and Spent Fuel Management

Grid Operations and Planning

Land and Groundwater

Substations and Asset Planning

Occupational Health and Safety

Transmission and Increased Power Flow

T&D Environmental Issues

Water and Ecosystems

Nondestructive Evaluation and Material Characterization

Equipment Reliability

Instrumentation and Control

Risk and Safety Management

Advanced Nuclear Technology (ANT)

Low-Level Waste and Radiation Management

Advanced Nuclear Technology (ANT) Program j Objectives • New nuclear power plants must overcome a number of regulatory, regulatory economic economic, technical technical, and social barriers prior to becoming a reality • Program efforts focused around: – – – –

Facilitating standardization across the new fleet Transferring technology to new plant designs Ensuring top plant performance from start of operations Reduce overall deployment risk and uncertainty

EPRI’s ANT Program…Leveraging the Industry

U.S. Nuclear Plants Sustaining ~90% Capacity Factor 91% Average Capacity Factor for 2007

Coal

Wind / Solar

What is the Problem? • Theorem 1 – 50% of the problems in the world result from people using the same words with different meanings • Theorem 2 – The other 50% of the problems result from people p p using g different words with the same meaning g

Project Goal • Develop a roadmap for New Nuclear Build data handover and configuration management • Develop a common data language and interoperability standard that will be used by the nuclear plant sub-tier sub tier suppliers through the suppliers through the EPC and reactor vendors and finally through to the owner and operator

Why? – The Numbers • The National Institute of Standards and Technology’s (NIST) study, study Cost Analysis of Inadequate Interoperability in the U.S. Capital Facilities Industry identified and quantified the efficiency losses in the U.S. capital facilities i d industry attributable ib bl to inadequate i d interoperability. i bili • The researchers very conservatively estimated those U.S. losses to be $15.8 billion in 2002 - two two-thirds thirds borne by owners and operators.

Why? – Pre-startup •Information management throughout the asset lifecycle is a key means to increasing the return on assets in modern process plants. Better information management can benefit new plants by:

– Providing contractual definition of information deliverables for a planned plant – Reducing the substantial costs of collating handover data against the installed asset base – Reducing R d i opportunity t it costs t b by b bringing i i a new plant up to full operating capacity faster

Why? – Post-startup • And can also benefit existing plants by:

– Increasing plant productivity towards the inherent asset maximums – Finding Fi di new efficiencies ffi i i iin maintenance i t and d operations – Streamlining the supply chain

What is EPRI’s Role? • Provide and assemble the industry expertise to achieve new nuclear virtual plant configuration management

– Provide the driving force to establish the nuclear industry standards – Work with other organizations (i.e. FIATECH and NIST) to capture, leverage and adapt existing expertise and standards – Monitor adoption p and p provide support pp as needed

EPRI Actions in Progress

• Standard Configuration Management Reference Model and Implementing Guideline (2009 2010) • Education Ed ti off industry i d t tto ensure supportt through th h some difficult times – Nuclear N l IIndustry d t D Data t H Handover d G Guide id (2009) • Establish nuclear n clear XML schemas for critical components (FIATECH AEX) (2009 – ongoing)

The Journey to Data Interoperability

“Closing the Loop” on the Lifecycle of Nuclear Plant Data Berry y Gibson IBM

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

K Knowledge lliiinformation could ld be easily S Suppliers A howner T Th Asset Technicians The idif could and could ld di its ib seamlessly ld and access suppliers dlilprocesses licaptured l work h hand could k ddldwere over asset Outage projects and complex and replicated across different plants rigorously instructions collaborate information controlled using containing to a single owners… according richauthoritative 3D and data to best reduce and maintenance tasks could be simulated in the start-up fleet… so that best practices plant practices… process source ofinformation… plant sotime that definition… and licensing, to cost? guarantee and siting design and the and optimized for time and safety… became standard? regulatory right and construct work is audits performed thewere mostaefficiently correctly? breeze? prior

to expensive operated t d and dcapital maintained i t commitments? i d plant… l t together?

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

IBM/DS PLM Strategy : PLM 2.0, “PLM Online for All” 4 3D Lifelike Experience

Collaborative Innovation

Realistic Simulation

Lifelike Experience

2 3

Product Lifecycle M t Management

PLM 2.0 20 Users • All Users’ • Interactions

Digital Mock-Up

PLM 1.0 2D to 3D

3D 1981

1994

2000

2005

IP • Generate in 3D • Experience • Online

Harnessing Collective Intelligence

2011

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

IBM/DS PLM Strategy gy : How Will Nuclear Catch Up? 4 3D Lifelike Experience

Collaborative Innovation

Realistic Simulation

Lifelike Experience

Where Will Nuclear of the Future Be?

2 3

Product Lifecycle Management

1 Digital Mock‐Up

Today’s Nuclear Stuck with 70’s Practices 2D

PLM 2.0

PLM 1.0

•All Users •Users’ Interactions •Generate IP •Experience in 3D •Online

2D to 3D

1970

1981

1994

2000

2005

2011

2016+

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

PLM Vision for New Nuclear Full lifecycle virtual plant data Data, tool and process Data interoperability Data traceability

PLM Principles Work products should be produced on demand ALL plant information accessible through a common data model (i (i.e., e data data-centric centric object model) – Requirements and their evolution – Design decisions and their rationale – Changes and their justification – Project P j t and d contract t t data d t – Maintenance information through decommissioning – etc Use off-the-shelf technologies to provide data organization and visualization

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

Learning g from other Industries Challenges are principally the same – Key design challenges shared by other industries, such as Aerospace / Shipbuilding / Offshore Platforms – Complex capital projects, projects large number of parts parts, highly regulated regulated, global collaborative effort / many participants, reuse of data, IP capturing

IBM Software Group â&#x20AC;&#x201C; Collaborative Solutions for the Plant Lifecycle

As-Is Challenge g in Nuclear Design Requirements

What is required to be there The Physical Configuration

Configuration Information

Manual Processes Lots of Paper Disconnected Systems

What is there *Ref INPO AP-929

Must Conform

What we say is there

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

“Opportunities” pp With the As-Is Existing plants defined in 2D on drawings and in documents across systems that are not generally integrated Little industry experience with modern 3D design, SOA, data integration, etc. Data interoperability is painful to non-existent Information “handover” handover is not seamless Owner/Operators don’t get what they need from EPCs because of economics, contracts, experience, etc. Supply chains are much more complex and global than they were 30 years ago ago. High costs incurred to reduce configuration management risks – Maintaining design basis documents – Ensuring the physical plant matches design requirements and plant documentation – Keeping operating procedures up to date and in synch with design basis – Streamlining integration of maintenance and engineering data to support maintenance – Possibility of long-term plant shutdowns due to information inconsistencies – Performing V&V activity on the correct plant configuration Ref. SCE

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

Typical yp Project j Execution “System” y Today y Risk-Share Partner Contractor

Supplier

Preferred Parts Approved Vendors

Subcontractor

Constructability Reviews Build Plan Work Packages Tag and Master Index

E-mail

Procurement

Requirements Design Feedback MTOs BoMs Tag g Data Changes

Design Subcontractor

Construction Tech Pubs Field Notices

Engineering

Models Drawings Schematics

Service

S SneakerNet k N t

Business Development

FTP

Supplier

Concepts p Market Requirements Brochures Data Sheets

As-Maintained BOM Customer Concerns Corrective Action Work Instructions

Program Management

Courier

Risk-Share Partner

Contractor

Schedule Cost Risk EV

Requirements WBS SOW

Government

O/O Regulator

IBM Software Group â&#x20AC;&#x201C; Collaborative Solutions for the Plant Lifecycle

Typical Current Plant Information Environment Includes a number of offline applications and data sources Platform Business Unit

Marketing & Sales requirements

PAC

Engineering Costing (Guess Work)

Other data

Smartplant p

Engineer Assumption Requirement

Supplemental PCR

FMEA

Base PCR

DVR DVP&R

EMR Concept Sheet Development

Certification Process

DVR (Prototype Release)

Report

Information Search

15 Panel chart

9 Panel chart

Report

Test Supplier

Cost Analyst

Outsourcing

CAE Report

Cost BOM

Cost Analyst

Cost Report

(AS 400)

Program Team Report

Program Engineer

M d l Model

Report

Purchasing PRTM

Program master BOM

Production BOM Storage

Cost Cube

Report

Designer

Supplier

3D Drawings

Engineering Operations JBA

2D CAD Visualization

2D Drawings

Construction 2D CAD Visualization

Process Coordinator

(Prototype Engineering)

Process Coordinator

Designer

AME Engineer

Program Manager Inventory Management

Metrics Tracking

JBA

Pac Report

(Engineering)

SAP Information Search

MSP

Maintenance file

Report

Supplier

Logistics Management

Supplier

Routing file

JBA (Manufacturing)

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

PLM Architecture – Example Future Plant Information Environment 3D Dashboard Portal

System Model

Enterprise PLM System Model

Enterprise Service Bus (SOA)

Req. Mgmt DOORS

EAM Maximo

ISO 15926

ISO 15926 Primavera Scheduling

Process Sim DM Bentley

DM Intergraph

DM Catia

ERP

DM Aveva

DM CAE

Distributed PDM Point Solutions

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

PLM Architecture – Supports the Nuclear Plant Lifecycle VIRTUAL CONSTRUCTION

PROJECT LIFECYCLE MANAGEMENT

SIMULATION

Enterprise PLM

REAL--TIME REAL OPERATIONS System Model

PLANT DATA AUTHORING Customer Requirements Specification

Customer Requirements

Captured as

Specification

REQUIREMENTS ANALYSIS

Chapter Requirement Comment

MAINTENANCE, SAFETY, TESTING

IBM Software Group â&#x20AC;&#x201C; Collaborative Solutions for the Plant Lifecycle

The Vision: An Optimized Project Execution System Subcontractors Supplier Suppliers Constructability Reviews Build Plan Work Packages Tag and Master Index

Preferred Parts Approved Vendors

Requirements Design Feedback

Risk Share Contractor Partner C t Contractor t

Procurement

Construction Tech Pubs Field Notices

MTOs BoMs Tag Data Changes

PLM

Engineering

Models Schematics Drawings

Business Development Risk-Share Partner Design Partner Design Partner

Concepts p Market Requirements Brochures Data Sheets

As-Maintained BOM Customer Concerns Corrective Action Work Instructions

Service

Program Management Schedule C t Cost Risk EV

Requirements WBS SOW

O/O Customers Government

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

What are some of the things you could do with an integrated datacentric PLM execution environment? Project Planning Project Planning

Construction Planning Construction Planning

Logistics Logistics

• Manage a complete integrated Bill of Material for the whole p plant (p (piping, p g, mechanical,, electrical,, electronics,, software, etc) • Manage as-specified, as-designed, as-planned, asbuilt, as-maintained representations, as an evolving baseline, linked throughout the lifecycle • Execute projects with integrated project and plant data

Material Flow Simulation Material Flow Simulation

Operations Planning Operations Planning

• Perform maintenance activities on the right configuration with reference to model-based work instructions

Human Factors Human Factors

• Perform operator and maintenance training using configuration managed virtual reality representations of the plant

Maintenance Planning Maintenance Planning

• Plan, simulate and optimize construction processes using the same virtual plant model

Work Instructions Work Instructions

• Re-use plant definition data across functions and processes • Understand project status with integrated information Ergonomics & Safety Ergonomics & Safety 1

3D Job Aids 3D Job Aids

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

PLM Enablers for Key Configuration Management Functions CM Planning & Management Project Management Resource Management Role Assignment Schedule Management Primavera Integration Ri k M Risk Managementt Action Items

Configuration Identification Digital Plant Definition

Plant Breakdown Structure

Document Management

Customer Supplier Quality Mgmt

Ch Change Workflow Problem Report (PR) Enterprise Change Request (ECR) Enterprise Change Notice (ECN) Collaborative Change Impact Analysis

Metadata Attributes

Collaboration Mgmt

Configuration Control

Requirements Management

Document Associativity to Changes CAD data p Markups Reports Change Classification & Prioritization

Collaborative Design Reviews and Markup Effectivity g Management

Process Management Workflow Automation Lifecycle Management Dashboard Metrics and Reports

Document-to-Part Associativity

Status Accounting Change Lifecycle Ch Lif l Management Metrics and Reports Change Status Change Metrics BOMs Parts Lists “Where Used”

Verification And Audit Deliverables Management

Scheduled Delivery Dates Digital Content Package Acceptance Criteria

Modeling and Simulation

Structured Document Management Embedded Visualization Archival and Recovery ITAR Security and Access Control A dit Trail Audit

Serial / Lot / Date

Virtual Prototyping

Metrics and Reports

Full text searching Change Status Monitoring

CAD/CAM Models and Drawings Analysis Test Data Electronic Signatures A D i As-Designed d Etc. As-Built As-Maintained Configuration Alternates & Substitutes Baselining BOM-Compare Tools

PDF Document Collaboration Internet-Based Architecture

*ANSI/EIA-649 National Consensus Standard for Configuration Management

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

XCEL Energy gy – Monticello GEZIP Project j

? =

GEZIP = General Electric Zinc Injection Module

IBM Software Group â&#x20AC;&#x201C; Collaborative Solutions for the Plant Lifecycle

Entergy gy - Waterford 3 Steam Gen Removal

? =

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

IBM Center of Excellence for Nuclear Power La Gaude, France Austin, Texas

MISSION

Develop innovative information technology solutions and demonstrations Define and share best practice business processes for nuclear power Provide nuclear power participants with SOA tools and consulting methodologies g Architect a robust IT infrastructure to support the deployment of strategic enterprise applications by operators and plant designers

SOLUTIONS

CLIENTS

Th Nuclear The N l P Power E Ecosystem: t Business Process Solutions:

Owners/Operators

Designers/Constructors

Nuclear Best practices

Nuclear Service Providers:

Business Modeling

Nuclear regulatory/industry bodies:

Business Transformation

Knowledge Management

NRC, CEA, NEI, INPO, ASN,…

Nuclear R&D:

Integration Solutions:

ITER, GNEP, …

SOA Solutions

Academia

WebSphere Solutions

Application Solutions:

PLM, EAM, ECM, PDM, and others

Infrastructure Solutions:

HPC: Blue gene, Clusters, …

Locational Awareness, Security: RFID, video surveillance,...

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

La Gaude Scenario Overview

Detect Incident

G Generate t Work W k Order Od

B ASAP: Asset repair

Monitor Maintenance History KPI

Repair Asset KPI OK ÆNothing to do for now

KPI KO

Æ Issue

Work Order Update WorkUpdate Order F

C t E Create Engineering i i Issue I Work W k Order Od

Qualify Engineering Issue

Understand Plant Item Context

Consult Maintenance History

Maintenance Technician

Analyse y Impact: p Decide change g

Select New Supplier / Plant Item

Sign Off Engineering Issue

Update Engineering Issue Work Order

L GM Engineering Manager

D Enterprise Service Bus (WebSphere)

Maximo

A B

Engineer

ENOVIA

C J

J KI H

E Maintenance Manager

IBM Software Group – Collaborative Solutions for the Plant Lifecycle

Closing C os g tthe e Loop oop o on tthe e Lifecycle ecyc e o of Plant a t Data ata “PLM”

“EAM” Maximo Service Information Service Performance Analysis

Construction Planning O&M Simulation

Plant Design

Design Configurations, Information & Procedures

Plant Requirements

Equipment Utilization & Performance Analysis

Asset Configurations Information & Procedures

Service Optimization Plant Optimization

Upgrades & Revamps Inventory & Procurement Preventive e e t e Maintenance Service Forecasting & Planning

Work Instructions

The Ph hysical Plantt

The V Virtual P Plant

Release To Production

Operational Records Management

Drives Continual Plant & Service Improvement & Reduced TCO

IBM Software Group â&#x20AC;&#x201C; Collaborative Solutions for the Plant Lifecycle

As-Is Challenge g in Nuclear Design Requirements

What is required to be there The Physical Configuration

Configuration Information

Manual Processes Lots of Paper Disconnected Systems

What is there *Ref INPO AP-929

Must Conform

What we say is there

IBM Software Group â&#x20AC;&#x201C; Collaborative Solutions for the Plant Lifecycle

The Technology gy is Here Today y to Maintain Configuration g Using g Modern Technologies What is required to be there

Req. Mgmt DOORS

Configuration Information

The Physical Configuration Release To Production

O&M Simulation

Plant Design

Service Performance Analysis

Design Configurations, Information & Procedures

Plant Requirements

EAM Maximo

What is there

Operational Records Management

Service Information

Construction Planning

Equipment Utilization & Performance Analysis

Service Optimization Plant Optimization

Upgrades & Revamps

Asset Configurations Information & Procedures

Inventory & Procurement Preventive Maintenance Service Forecasting & Planning

System Model

Work Instructions

PLM Enovia

What we say y is there

IBM Software Group â&#x20AC;&#x201C; Collaborative Solutions for the Plant Lifecycle