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CMBG2009 Nuclear Configuration Management

Technology Solutions

June 30, 2009

Kent FreelandVanya Yordanova

WorleyParsons Europe Energy ServicesRISK Engineering Ltd.

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CMBG2009 Overview

• 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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CMBG2009 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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CMBG2009

Nuclear Power Renaissance

• New Attention to Nuclear Safety, Engineering and Business Efficiency

• Better understanding of Configuration Management and the elements that create CM, including:

o Design Basis Management o Nuclear Knowledge Management o Plant Lifecycle and MRO o Asset Management o Plant Life Extension o 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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CMBG2009

Nuclear MRO Solution

Asset Management

Design Basis

Nuclear MRO Solution

Engineering Change Process

Plant Life Extension

Plant Maintenance and Operation

Knowledge Management

Nuclear Business Functions

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CMBG2009

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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CMBG2009

Technology Evolution2009• 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, open-source 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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CMBG2009 New Industry Profile for Configuration Management

and Asset Management in 2009• 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 well-known,

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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CMBG2009

IT Solutions that support Nuclear Business ModelsNuclear Operations, Engineering and Maintenance require IT solutions that perform the following:• Track and manage the business processes to operate the NPP, such as Maintenance,

Engineering, Parts and Warehouse, Operations and Purchasing/Procurement. • 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.

• Provide for Requirements Management, to support Licensing, Engineering, Maintenance and Action Tracking requirements.

• Provide and support an infrastructure to coordinate, collaborate and communicate plant events and changes instantly to all concerned organizations.

• Support “3-D” Computer Aided Design (CAD) for utilization in engineering, plant modeling, component identification, and to support paperless design.

• 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.

• 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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CMBG2009

Technology Comparison: PLM vs. legacy Repository-based

Manual or e-mail-based Collaboration and CM processes

FIXED RELATIONAL (RDBMS) DATA REPOSITORYFIXED RELATIONAL (RDBMS) DATA REPOSITORY

PROGRAMS AND LEGACY CODEPROGRAMS AND LEGACY CODE

PROCESS

LEGACY DATA SOURCES

Traditional Relational 3rd/4th Generation (1980’s) “Repository” Solution

Table Keys and RDBMS Cardinality

Controls

Manual or e-mail-based Collaboration and CM processes

FIXED RELATIONAL (RDBMS) DATA REPOSITORYFIXED RELATIONAL (RDBMS) DATA REPOSITORY

PROGRAMS AND LEGACY CODEPROGRAMS AND LEGACY CODE

PROCESS

LEGACY DATA SOURCES

Traditional Relational 3rd/4th Generation (1980’s) “Repository” Solution

Table Keys and RDBMS Cardinality

Controls

Process-based XML Plant Lifecycle Management (PLM) Solution

XML DATA REPOSITORYXML DATA REPOSITORY

IDE/Eclipse PROCESS MODELINGIDE/Eclipse PROCESS MODELING

Lifecycle VisualizationCollaboration & Configuration

EQUIPMENT & BOM

EQUIPMENT & BOM

NPP DOCUMENT CONTROL

NPP DOCUMENT CONTROL

Document Management

ENGINEERING CHANGE

CONTROL

ENGINEERING CHANGE

CONTROLCATALOG & MATERIALS

CATALOG & MATERIALS WORK

MANAGEMENT

WORK MANAGEMENT

Supplier Relationship

Enterprise Knowledge

PLM & CONFIGURATION INFRASTRUCTUREPLM & CONFIGURATION INFRASTRUCTURE

NPP BUSINESS

RULES

NPP BUSINESS

RULES

Typical NPP Business Processes

PLM Functions

Client Interaction and Business Rules

Data

XML Data Messaging and Linking

Process-based XML Plant Lifecycle Management (PLM) Solution

XML DATA REPOSITORYXML DATA REPOSITORY

IDE/Eclipse PROCESS MODELINGIDE/Eclipse PROCESS MODELING

Lifecycle VisualizationCollaboration & Configuration

EQUIPMENT & BOM

EQUIPMENT & BOM

NPP DOCUMENT CONTROL

NPP DOCUMENT CONTROL

Document Management

ENGINEERING CHANGE

CONTROL

ENGINEERING CHANGE

CONTROLCATALOG & MATERIALS

CATALOG & MATERIALS WORK

MANAGEMENT

WORK MANAGEMENT

Supplier Relationship

Enterprise Knowledge

PLM & CONFIGURATION INFRASTRUCTUREPLM & CONFIGURATION INFRASTRUCTURE

NPP BUSINESS

RULES

NPP BUSINESS

RULES

Typical NPP Business Processes

PLM Functions

Client Interaction and Business Rules

Data

XML Data Messaging and Linking

XML DATA REPOSITORYXML DATA REPOSITORY

IDE/Eclipse PROCESS MODELINGIDE/Eclipse PROCESS MODELING

Lifecycle VisualizationCollaboration & Configuration

EQUIPMENT & BOM

EQUIPMENT & BOM

NPP DOCUMENT CONTROL

NPP DOCUMENT CONTROL

Document Management

ENGINEERING CHANGE

CONTROL

ENGINEERING CHANGE

CONTROLCATALOG & MATERIALS

CATALOG & MATERIALS WORK

MANAGEMENT

WORK MANAGEMENT

Supplier Relationship

Enterprise Knowledge

PLM & CONFIGURATION INFRASTRUCTUREPLM & CONFIGURATION INFRASTRUCTURE

NPP BUSINESS

RULES

NPP BUSINESS

RULES

Typical NPP Business Processes

PLM Functions

Client Interaction and Business Rules

Data

XML Data Messaging and Linking

Traditional “Repository”-based System Architecture

Primarily COLLECTS Data for later Retrieval, Analysis, Reporting or

Archive.

“Plant Lifecycle Management (PLM)”-based System

Architecture

Primarily MOVES Data and Events for immediate application

to CM-, Knowledge- or Asset-based tasks

You must know what you need to retrieve information

You must know that you need to retrieve it NOW.

Appropriate information is delivered to you when you need it.

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CMBG2009 New factors in the “Buy/Build” Decision Tree

Approaches• Develop and program the NPP Nuclear IT solution 100% in-house, to be deployed on

the selected target architecture.

• Purchase and deploy a turnkey IT MRO solution, which may include an integrated ERP host architecture migration (such as SAP or Oracle-based products).

• Design and deploy a hybrid solution of in-house and commercial IT elements.

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CMBG2009

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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CMBG2009

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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CMBG2009

Sample Development of PLM-based Nuclear Power Technology Solution

Asset Management

Design Basis

Nuclear MRO Solution

Engineering Change Process

Plant Life Extension

Plant Maintenance and Operation

Knowledge Management

PLM replaces often ambiguous MRO system links and interfaces with a single point of contact for Configuration Management and Design Control.

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CMBG2009

Integration of Legacy Data Management and Outboard Applications

Data Generation

Data Review/ Approval

Enterprise CM

Data is as

completeas possible

Data is

validated as much as possible

PR

OC

ES

S C

ON

TR

OL

CADD, construction data, Intergraph PDS, simulation, CAE, engineering data sheets, Action Items, CARs, project management, etc.

Document Manager (EDMS), Engineering Workflow & Routing (eProcess EDR), Action Tracking.

MEL, DCM, ECC, Materials, Work Management, etc.

Concept & Design DataConcept & Design Data

Design & ConstructionDesign & Construction

OperationOperation

PLM

PLM

A “Tier”-based deployment plan for Enterprise NPP Solution for Design,

Construction and Operation Phases of plant development

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.

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CMBG2009

Integration of Legacy Data Management and Outboard Applications

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.

• 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.

CADD Data DM DCS QRM

Computer-Aided Drafting/Design Design/Construction Data Document Creation & Management Nuclear Document Control System Quality Records Management

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CMBG2009 Questions?