Design Knowledge Management for the Power Industry. Opportunities, Challenges and Lessons Learnt

Transcription

1 Design Knowledge Management for the Power Industry. Opportunities, Challenges and Lessons Learnt Kevin Gribbin November 2014.

2 Topics Intergraph - Who we are - What we do DKM and CMIS Current State Integration and Automation Opportunities Handover Turnover Future State Questions

3 Introduction Kevin Gribbin Director, Integrated Management Systems Global Power Group Global Presence Responsibilities SEA India Europe South Africa 35 years of Information/Configuration Management Experience

4 PP&M Worldwide Representation 3,000 Intergraph PP&M team members offer services and support in more than 40 countries

5 Intergraph Technology Portfolio /2/2014 Intergraph Corporation. All Rights Reserved

6 Standards and Open Platform Standards Exchange standards, CCITT Group IV, CGM Content standards De facto File Format Standards Direct Interfaces (APIs) Alliances Open Platform Microsoft operating systems Relational databases Development environment Integration frameworks & portal 6

7 What is a CMIS? Configuration Management and Information System is an advanced plant information management system for nuclear power plants. Configuration management helps ensure the plant s safe operation by providing fast & reliable answers to these fundamental questions: For any item or system in my plant, what are the relevant design documents and governing requirements & regulations? For any regulatory document or design basis document, what are the affected items or systems in my plant? What documents do I have that prove the systems in my plant are operating in compliance with the above? What tags are in a particular system and what is the manufacturer and model number of each? Where in my plant are the following tag numbers located? What drawings contain these tags and when was the drawing last updated? 7

8 What is CMIS and who requires it? NRC's regulations are found in Chapter I of Title 10, "Energy," of the Code of Federal Regulations (CFR). Principal parts governing the licensing and operation of nuclear reactors: Part 26 - Fitness-for-duty programs Part 50 - Domestic licensing of product and utilization facilities Part 51 - Environmental protection regulations for domestic licensing and related regulatory functions Part 52 - Early site permits; standard design certifications; and combined licenses for nuclear power plants Part 54 - Requirements for renewal of operating licenses for nuclear power plants 12/2/2014 Part Reactor site criteria In many countries, regulatory authorities require a CMIS to obtain an operating permit. CMIS may include document management capability, but a document management system is not a CMIS. CMIS principles being defined by the nuclear industry. Institute of Nuclear Power Operations (INPO) AP929 Configuration Control Institute of Nuclear Power Operations (INPO) INPO New Plant Configuration Management Development & Implementation Process ANSI/NIRMA CM Configuration Management of Nuclear Facilities IAEA TecDoc 1335 Configuration Management in Nuclear Power Plants

9 Key Industry Publications & Recommended Practices EPRI: Advanced Nuclear Technology: New Nuclear Power Plant Information Handover Guide (2009) Elements of Pre-Operational and Operational Configuration Management for a New Nuclear Facility (2011) IAEA: Safety Reports Series No.65 Application of Configuration Management in Nuclear Power Plants (2010) Managing the First Nuclear Power Plant Project (2007)

10 The CHALLENGE: Managing and Controlling Change From 2009 EPRI Report New Nuclear Power Plant Information Handover Guide : Configuration Management is a set of processes, practices, and tools necessary to effectively manage all the obligations regarding the design, construction, operation, maintenance, and decommissioning of a NPP, thereby maintaining consistency between the design and licensing basis requirements (what needs to be there), the physical configuration (what actually is there), and the configuration information (what we say is there). Design & Licensing Basis Information (DLBI) is one of the cornerstones of configuration management.

11 . DKM and CMIS

12 Integrated CMIS Scope CMIS Scope 12

13 Configuration Management: A Lifecycle Approach A/E or NSSS Vendor Reference Plant or Reactor Development Project Award Prime Contractor Site Specific Project Project Turnover Plant Operator Generating Plant System Tools Tools Tools Reqs. DB MCAD & Other Data Load Handover Load Other App Data CMIS A For A/E or NSSS Data Load Handover Load Data & Documents from Vendors, Contractors, etc CMIS B For Prime Contractor Turnover Load Other Data & Documents CMIS C For O/O CM principles begin in design with effective change management and data correlation between disciplines ITAAC Tracking CMIS A manages design basis, deliverables, tests & requirements Inquiries & Commitments with owner, regulators, others ITAAC Tracking CMIS B manages design basis, procured items, construction, tests, commitments & requirements IST Tracking Inquiries & Commitments with regulators, others CMIS C manages design basis, assets/ssc s; margin & requirements, In-Service Testing, operations support

14 Configuration Management: Task and Purpose A/E or NSSS Vendor Reference Plant or Reactor Development Project Award Prime Contractor Site Specific Project Project Turnover Plant Operator Generating Plant System Tools Tools Tools Reqs. DB MCAD & Other Data Load Handover Load Other App Data CMIS A For A/E or NSSS Data Load Handover Load Data & Documents from Vendors, Contractors, etc CMIS B For Prime Contractor Turnover Load Other Data & Documents CMIS C For O/O CM principles begin in design with effective change management and data correlation between disciplines ITAAC Tracking CMIS A manages design basis, deliverables, tests & requirements Inquiries & Commitments with owner, regulators, others ITAAC Tracking CMIS B manages design basis, procured items, construction, tests, commitments & requirements IST Tracking Inquiries & Commitments with regulators, others CMIS C manages design basis, assets/ssc s; margin & requirements, In-Service Testing, operations support

15 The Classic Three-Ball Model of Configuration Management Enhanced Model (Standard Equipment or Purchasing Domain = typical Build from Print) Pump Catalog Engineering Domain = logical N Centrifugal Model # CP-C Operations Domain = actual Tag (functional location) 1 Specifications: RPM: 1500 Material: Cast Steel 316 Model or Std Equipment what we can purchase to fulfill the process need Asset (inventoried item) N P-101 Logical or Functional Location what are the characteristics to fulfill the process need 1 and, if it breaks, where are the spares or where can we find a similar model? 1 Actual or Physical what we have installed to fulfill the process need

16 Configuration Management: A Lifecycle Approach Tools Tools Tools SPRe Reqs.L Cons. CM principles begin in design with effective change management and data correlation Construction between disciplines planning, mat l mgt, Consolidation and ITAAC tracking activities may also occur in Reference Design phase For A/E or NSSS MCAD & Other ITAAC Tracking Load Other App Data Product CMIS For O/O Operational CMIS manages design basis, assets/ssc s; margin & requirements, In-Service Testing, operations support, and is the integration hub to ERP and CMMS systems and, in the near future, security analytics PID I&C 3D Product CMIS manages design basis, deliverables, tests & requirements Load Other Data & Documents Operational CMIS Inquiries & Commitments with regulators, others Reqs. Cons. IST Tracking Load Data & Documents from Vendors, Other Contractors, etc Pre- Operational CMIS Inquiries & Commitments with owner, regulators, others Mat & Cons. For Prime Contractor ITAAC Tracking Pre-Op CMIS manages design basis, procured items, tests, NCRs, commitments & requirements for ongoing project; validation zone for data to be handed over

17 Configuration Management: A Lifecycle Approach Tools Tools Tools SPRe Reqs.L Cons. CM principles begin in design with effective change management and data correlation Construction between disciplines planning, mat l mgt, Consolidation and ITAAC tracking activities may also occur in Reference Design phase For A/E or NSSS MCAD & Other ITAAC Tracking Load Other App Data Product CMIS For O/O Operational CMIS manages design basis, assets/ssc s; margin & requirements, In-Service Testing, operations support, and is the integration hub to ERP and CMMS systems and, in the near future, security analytics PID I&C 3D Product CMIS manages design basis, deliverables, tests & requirements Load Other Data & Documents Operational CMIS Inquiries & Commitments with regulators, others Reqs. Cons. IST Tracking Load Data & Documents from Vendors, Other Contractors, etc Pre- Operational CMIS Inquiries & Commitments with owner, regulators, others Mat & Cons. For Prime Contractor ITAAC Tracking Pre-Op CMIS manages design basis, procured items, tests, NCRs, commitments & requirements for ongoing project; validation zone for data to be handed over

18 The Engineering Design Basis: Architecture ELE Electrical INST and Instrumentation schematics PFD Plant structures & Ref Data REF Documentation IOP PID Process and Instrumentation Diagram 3D PrcData Process Data sheets and tag indexes EQpData Mechanical Data sheets and tag indexes 3D Model and derived documentation

19 The Engineering Design Basis: Architecture ELE Electrical INST and Instrumentation schematics PFD Plant structures & Ref Data REF Documentation IOP PID Process and Instrumentation Diagram 3D PrcData Process Data sheets and tag indexes EQpData Mechanical Data sheets and tag indexes 3D Model and derived documentation

20 DKM Current State.

21 Typical Situation Document Management Configuration Management Requirements Management Design Basis (SSC s) Transmittals Operations and Maintenance Inspection and Testing Change Management

22 Typical Situation What is the Context Document Management 3rd party app Design Basis (SSC s) Why? Requirements Management What? When? Where? Operations and Maintenance Who? In-house app Inspection and Testing 3rd party app

23 Typical Situation What are the Risks Document Management 3rd party app Incompatible Formats Requirements Data Duplication/Replication Management Poor Information Integrity Complex Change Management No Auditability/Traceability Design Basis (SSC s) What/When/Who Operations and Maintenance Geometric IT Cost Curve In-house app Inspection and Testing 3rd party app

24 Integration and Automation Opportunities.

25 Why Integration and Automation Guidelines for Specifying Integrated Computer- Aided Engineering Applications for Electric Power Plants. EPRI (Electric Power Research Institute) report NP-5159M, Research Project , May 1987

26 Relative Annual Savings From Automation and Integration at an Average Nuclear Power Plant Data set savings Automation savings Integration savings Delta x increase in savings between automation and integration Equipment Tagout $69,000 $124, x Valve Index $21,600 $167, x Instrument Identification $17,800 $135, x Motor Index $15,200 $123, x Piping Index $12,000 $84, x Action Request $12,100 $44, x Commitment Tracking $5,000 $14, x Circuit Breaker Index $5,000 $37, x EPRI (Electric Power Research Institute) report NP-5159M, Research Project , May 1987

27 Affect on RAM (Reliability, Availability and Maintainability) by re-using the data more than once in other activities example equipment valve specs and associated activities [including:- performance monitor, performance analysis, reliability assurance, reactor safety, incident investigation, industrial safety assurance and analysis, valve/valve operator maintenance, maintenance procedure development, equipment history analysis, operational procedure development, emergency operations, operating experience evaluation] yielded an annual cost saving of $8M alone (in 1987!). EPRI (Electric Power Research Institute) report NP-5159M, Research Project , May 1987

28 Aggregation and Consolidation Discipline Information Discipline Information R&D Engineering Pump Duty: 1500m3/h Spec: AP610 Type: Centrifugal Location: Area B12 System: 27 (Potable Water) Function: Water Injection Tag No.: P-101 Materials: 25% Cr. Duplex Power: 550 kw Motor Tag: PM101 Procurement Construction Vendor: Sulzer Model No: 1173K74H Connections:16in Suction, 12in Discharge Weight: 11000kg Structure: Skid Seals: Crane BSTFN Power Supply: 11kv, 3ph, 60hz As Built: Dimensional data, Spool changes Test data: Inst. Records, pressure, Serial Number: 12993MN66 Planning WBS: 24 Site Lead: 20 days Unit Test: 5 days Hydro Test : 2 days Completion: 20July2002 Estimating Pump Duty: 1500m3/h Number Required: 20 Cost Per Unit: $3000 Controls Operations Maintenance Comm Records: Performance, NPSH Control Settings, Operating Limits Operating records: MTBF Performance curves IOM Procedures, QC Test: Hydro, String, Performance Equipment replacement & spares data, Lubrication and strip down records

29 Value to the business Tiers of Integration Leverage Integrated Composite Applet Implementation Messaging Business Process Integration Transport Application Integration Consolidation Data Integration Presentation Access Integration Effort to Deploy

30 Handover Turnover What does this mean?.

31 Engineering data in Execution is stateful, volatile, temporal and spread across disparate sources and owners Specifications & Standards Process Simulation Project Management Instrumentation Design Instrument Data Sheets PFD Requistioning Time allocation & measurement Hazop Automation & Control Design Contracts P&ID Mechanical Equipment Design Electrical Design Procurement Cost Controls Progress Management Plant 3D Modeling HVAC Equipment Data Sheets SLD s & Schematitcs GA s and ISO s Civil & Structural Supplier Gateway Line Lists Shipping EDMS Valve Lists Cabling & Lighting Document Control Equipment Lists Project Portal Hook up & Installation Construction Sequencing Test & Commissioning EPC where time TO market is imperative planning logic connectivity layout actual completion

32 Engineering data in Operations spreads across multiple plant operational systems and time domains Extended Supply Chain Supply Chain Enterprise Plant Production Unit Production Process Machine SCADA Data Capture Control Logic Product / plant Lifecycle mgmt Batch Mgt SPC / Trends Automation Specialty Quality Admin In Process Testing Process Automation Product Specs EDMS Process Planning Optimisation Formula Mgt MES Data Historian Plant Centric ERP LIMS ERP Financials Procurement FCP Factory Schedule CRM Reliability monitoring & optimization Trading Exchange Supply Chain OO where time IN market is imperative Machine Logic Process Control SPC Process Mgt Recipe Work Order Execution Plant Operations Production Schedule Business Process Supply Chain Customer Original diagram source courtesy: AMR Research

33 Handover & Uploading Specifications & Standards Process Simulation Project Management Instrumentation Design Instrument Data Sheets PFD Requistioning Time allocation & measurement Hazop Automation & Control Design Contracts P&ID Mechanical Equipment Design Electrical Design Procurement Cost Controls Progress Management Plant 3D Modeling HVAC GA s and ISO s Civil & Structural Equipment Data Sheets SLD s & Schematitcs Supplier Gateway Line Lists Shipping EDMS Valve Lists Cabling & Lighting Document Control Equipment Lists Project Portal Construction Sequencing Hook up & Installation Test & Commissioning EPC ERP CRM Trading Exchange Control Logic SCADA Data Capture Product / plant Lifecycle mgmt Specialty Quality Admin Batch Mgt SPC / Trends Automation In Process Testing Process Automation Product Specs EDMS Formula Mgt Process Planning Optimisation Data Historian MES Plant Centric ERP FCP Factory Schedule LIMS Financials Procurement Reliability monitoring & optimization Supply Chain OO

34 . Future State

35 Inter-Relationships across line-of-business systems Des Op Press: 150psi Supplier: Simmons BOM: 24X89/P101 Des Op Press: 100psi Asset no: 24X89 Maint Proc: MM101 Manfr: Weir Model: CP-C-4020 Tag: P-101 Plant: Texas2 Purchase Order: U9735 System: 20 Separation Spec Document: C056-KIV-1-DS-2001 P&ID Drawing: C056-SA-P-XR What documentation What did What we we can buy What Who need is be which the we obtained and are did supports at plant s need we the its is so capabilities at get functional to configuration the the it maintain fulfill from functional licence the location it need and location safety data sheet

36 Hierarchical VS Molecular Most hierarchical Information Management systems model their information as represented by the familiar cabinet folder file paradigm.

37 Think instead of objects and relationships as molecular

38 Data Centralization API API API

39 Management Communication /31/2011 Intergraph Corporation. All Rights Reserved 39

40 View by Reason for Issue 40

41 SAFETY QUALITY PRODUCTIVITY

42 QUESTIONS!