Transcript MANAGEMENT REVIEW MEETING

CMBG
2009
Nuclear Configuration Management
Technology Solutions
Kent Freeland
Vanya Yordanova
WorleyParsons Europe Energy Services
RISK Engineering Ltd.
June 30, 2009
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CMBG
2009
Overview
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Nuclear Power Renaissance: New Attention to Nuclear Safety,
Engineering and Business Efficiency
Information and Process Technology has significantly evolved
since 1980’s, and more fully integrate CM with existing processes.
New Industry Profile for Configuration Management and Asset
Management.
Enterprise-level IT Solutions that support Nuclear Business Model,
MRO and Configuration Management requirements.
Technology comparison: PLM vs. legacy Repository-based
New factors in the “Buy/Build” Decision Tree
Sample Development of PLM-based Nuclear Power Technology
Solution
Integration of Legacy Data Management and Outboard
Applications
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CMBG
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Types of NPP IT Solutions for CM
Departmental Systems (VBNET, Archimed, etc.)
Enterprise NPP Maintenance Resource Optimization
(MRO) or “CM” system – Technical CM Control
Enterprise Resource Planning (ERP) system (SAP,
Oracle, Internal) – Financial CM Control
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2009
Nuclear Power Renaissance
• New Attention to Nuclear Safety, Engineering and Business
Efficiency
• Better understanding of Configuration Management and the
elements that create CM, including:
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Design Basis Management
Nuclear Knowledge Management
Plant Lifecycle and MRO
Asset Management
Plant Life Extension
Nuclear Business Processes
• These functions are often regarded as nuclear business
processes, with Configuration Management a collateral
benefit.
• Actually, The converse is true: Configuration Management is
the principal means to support and facilitate these functions.
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Nuclear Business Functions
Asset Management
Engineering Change
Process
Knowledge
Management
Plant Life Extension
Design Basis
Nuclear
Nuclear MRO
MRO Solution
Solution
Plant Maintenance and
Operation
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CMBG
2009
Technology Evolution
Information and Process Technology has significantly evolved since 1980’s, and
more fully integrates CM with existing processes.
1980’s – 1990’s
• Centralized computing on expensive, enterprise-based Mainframe
or large Departmental computers and hardware.
• Expensive, resource-intensive operating systems and complex
2nd/3rd -generation programming languages.
• Large, complex and proprietary Relational-design databases with
limited choice of design tools and fast obsolescence.
• Limited GUI Choices
• Processes and business rules are indelibly coded into the software,
and are difficult to adapt to individual NPP work processes,
procedures and culture.
• No Internet
• Nearly impossible to achieve true Nuclear Configuration
Management with these technologies
• Commercial Nuclear CM and MRO applications during this era are
resource-intensive, unpopular and astronomically priced.
• Internally-developed systems are maintenance-intensive and resist
change or update.
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CMBG
2009
Technology Evolution
2009
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De-centralized computing, or low-priced IP networks based on server-router
and LAN/WAN architecture.
Massive increases in computing power with simultaneous drop in cost.
Order-of-magnitude decrease in hardware and infrastructure costs.
Availability of inexpensive, or even free, operating systems and simple, opensource 4th/5th -generation programming environments and process modeling
environments (such as JAVA and IDE).
Alternatives to monolithic Relational databases and query facilities in the form
of SQL, XML and network-based database technologies.
Popularization of HTML and IP-based interface environments (.NET, .ASP,
etc.)
New software designs that permit users to easily tailor the baseline system
functionality to fit their job requirements and culture.
Universal Internet access
New Commercial Nuclear CM and MRO applications utilizing PLM and IDE
Modeling technologies are under development.
Internally-developed systems are far easier to develop and maintain, but the
requirement for the utility or plant to understand Nuclear Business, MRO and
Configuration Management is unchanged.
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New Industry Profile for Configuration Management
and Asset Management in 2009
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Today, the Nuclear Power Industry understands the goals and
requirements for effective CM better than ever.
Configuration Management is now better recognized as a key
element in overall NPP safety and viability.
The lessons of neglecting Configuration Management are now wellknown, including plant operating incidents, poor INPO performance,
forced plant shutdowns and expensive Design Basis Reconstitution
projects.
The role of CM in collateral benefits of plant safety, financial
performance, regulator confidence, personnel management and
knowledge base, and general efficiency are better appreciated than
in years past.
Recognition of a strategic direction for plant operating management
and lifecycle control is appearing in operating plants, and for
planning and construction of new builds.
Past NPP IT solutions have provided experience useful in evaluating
new technology and solutions available today.
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CMBG
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IT Solutions that support Nuclear Business Models
Nuclear Operations, Engineering and Maintenance require IT solutions that perform
the following:
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Track and manage the business processes to operate the NPP, such as
Maintenance, Engineering, Parts and Warehouse, Operations and
Purchasing/Procurement.
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Manage the processes for design basis and basic NPP configuration, such as
Master Equipment List, Document Review and Control, and Engineering
Design Changes and Procurement Engineering.
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Provide for Requirements Management, to support Licensing, Engineering,
Maintenance and Action Tracking requirements.
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Provide and support an infrastructure to coordinate, collaborate and
communicate plant events and changes instantly to all concerned
organizations.
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Support “3-D” Computer Aided Design (CAD) for utilization in engineering,
plant modeling, component identification, and to support paperless design.
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Provide a means to support long-term analysis of plant and component asset
condition and performance over life, providing both Repair/Replace/RTF
maintenance support and plant life extension.
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Furnish the means to identify, collect and provide access to critical plant
implicit and explicit knowledge to be captured as staff and vendors turn over.
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Technology Comparison:
PLM vs. legacy Repository-based
Traditional “Repository”-based
System Architecture
Primarily COLLECTS Data for later
Retrieval, Analysis, Reporting or
Archive.
You must know what you need to
retrieve information
You must know that you need to
retrieve it NOW.
“Plant Lifecycle Management
(PLM)”-based System
Architecture
Primarily MOVES Data and Events
for immediate application to CM-,
Knowledge- or Asset-based tasks
Appropriate information is delivered
to you when you need it.
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New factors in the “Buy/Build” Decision Tree
Approaches
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Develop and program the NPP Nuclear IT solution 100% in-house, to be deployed on
the selected target architecture.
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Purchase and deploy a turnkey IT MRO solution, which may include an integrated ERP
host architecture migration (such as SAP or Oracle-based products).
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Design and deploy a hybrid solution of in-house and commercial IT elements.
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Sample Development of PLM-based
Nuclear Power Technology Solution
Preparation
 Goal is: development of a Nuclear Power Generation enterprise technology solution
for NPP configuration management, asset management, and possibly design and
construction systems.
 Establish a comprehensive nuclear power generation Configuration Management,
Asset Management and functionality model to support system review/development.
 Use PLM for a type of “Instant Messaging” Configuration Management – notifies all
affected system users of change in process or plant configuration the instant it occurs.
 With 3-D Modeling technology, the solution should support the creation of a closed,
integrated CAD-to-Control Room system for end-to-end design control, as well as 3-D
plant model to facilitate design changes and identify components.
 The NPP should explore all alternatives, including new technologies and solutions as
legacy nuclear business technology solutions currently on the market, combined with
CM-based processes and configuration control features needed to implement a
Nuclear Configuration Management solution.
 Selected solution should match NPP IT Target Architecture to avoid undue burden on
infrastructure and existing systems.
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Sample Development of PLM-based
Nuclear Power Technology Solution
Architecture and Design Features
 Reduce complexity, interface and ergonomic issues traditionally associated with
cumbersome legacy, manual or rogue IT systems at NPP’s by following the legacy and
data development model (later in presentation).
 Look for advanced, 4th/5th generation software architecture and technology, preferably
utilizing a discrete process modeling environment (IDE), to capture business rules and
transaction processing with little or no software programming. Then, nuclear business
functionality stays persistent through systems software updates, versions and changes.
 System should accommodate an integrated ERP hub interface; this may be for SAP,
Oracle or custom utility-based system (which most are).
 A self-documenting design platform is preferred; there should be little or no need for
SDK’s and screen forms generators. Today’s IT organizations want to rely far less, if at
all, on outside software development and consulting.
 Users will be attracted to an interface that utilizes XML/HTML and offers a “web page”
look-and-feel.
 The product should be as modular as possible, along NPP functional lines, to facilitate
deployment timeliness or phased implementation.
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Sample Development of PLM-based
Nuclear Power Technology Solution
PLM replaces often ambiguous MRO system links and interfaces with a single point
of contact for Configuration Management and Design Control.
Asset Management
Knowledge
Management
Engineering Change
Process
Plant Life Extension
Plant Maintenance
and Operation
Design Basis
Nuclear MRO Solution
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Integration of Legacy Data Management
and Outboard Applications
Data is created, reviewed and approved over a prescribed content review lifecycle that
ensures the Configuration Management Integrity of the content. The process may be divided
into three “tiers” or levels, from the creation of the data or document, through the review and
approval of content and subsequent delivery to the enterprise CM/MRO system.
Concept & Design Data
Concept & Design Data
Data Generation
A “Tier”-based deployment plan for
Enterprise NPP Solution for Design,
Construction and Operation Phases of plant
development
CADD, construction data, Intergraph PDS, simulation, CAE, engineering
data sheets, Action Items, CARs, project management, etc.
PROCESS CONTROL
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Data is as
PLM
Design & Construction
Design & Construction
complete
as possible
Data Review/Approval
Document Manager (EDMS), Engineering Workflow
& Routing (eProcess EDR), Action Tracking.
PLM
Operation
Operation
Enterprise CM
Data is
validated as
much as possible
MEL, DCM, ECC, Materials, Work Management, etc.
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Integration of Legacy Data Management
and Outboard Applications
CMBG
2009
Systems Integration
• Data should be integrated and managed based on a CAD-to-Field architecture.
Legacy data,
such as engineering databases, CAD data, preliminary design and EPC data (for new builds
or design changes) should follow a path similar to that shown below. This creates a lifecycle
from creation to quality records where the development of the document/data is traceable and
has value as a CM tool.
CADD
Computer-Aided Drafting/Design
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Data
Design/Construction Data
DM
Document Creation & Management
DCS
Nuclear Document Control System
QRM
Quality Records Management
Systems integration not only addresses core plant business functions (vertical integration), but
those NPP business areas that supply data, documents and other objects to the CM system
(horizontal or flat integration). The design engineering area demonstrates a particularly strong
impact from CADD sources, raw design data repositories, data and specification sheets, and
niche data sources from industry and trade groups, which produce basic NPP documents and
quality records. The data repository and post-CAD data are of particular interest to design
and construction organizations, which follow a cohesive data- and document-creation and
distribution taxonomy that cannot be effectively followed without a PLM-type facility.
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Questions?
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