Extending the New Plant Design 3D Model Into an Operations and Maintenance Tool. Ken Barry Senior Project Manager

Transcription

1 Extending the New Plant Design 3D Model Into an Operations and Maintenance Tool Ken Barry Senior Project Manager

2 Objectives Extending the New Plant Design 3D Model Into an Operations and Maintenance Tool Ensuring that the necessary data is available Virtual plant configuration management Data Quality Assurance (QA) and Software Validation & Verification (V&V) 2

3 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 using different words with the same meaning Stan Kaplan, Risk Analysis, Vol 17,

4 What is the Solution? We need a common data language and standards that will be used by the nuclear plant sub-tier suppliers through the suppliers through the EPC and reactor vendors and finally through to the operator 4

5 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 costs by bringing a new plant up to full operating capacity faster Reducing the substantial costs of collating handover data against the installed asset base 5

6 Why? Post-startup And can also benefit existing plants by: Increasing plant productivity towards the inherent asset maximums Finding new efficiencies in maintenance and operations Streamlining the supply chain 6

7 Why? The Numbers The National Institute of Standards and Technology s (NIST) 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 industry attributable to inadequate interoperability. The researchers very conservatively estimated those U.S. losses to be $15.8 billion in

8 What is Configuration Management (CM)? EDB Engineering Design Basis per 10CFR50.2 What needs to be there Conform Conform Physical Plant What is actually there PP Conform PD Plant Documentation What we say is there Work Processes must assure that: Elements conform all the time All changes are authorized Conformance is auditable 8

9 Issues with the old way Existing plant CM is based upon paper (P&IDs) does not take advantage of computer technology and can be at odds with existing technology SSC Data from suppliers has to be captured with human intervention Adoption of formal change management processes demands a great deal of linkage between manual processes and separate databases Existing change management is reliant upon tribal knowledge 9

10 How is the CM process impacted by use of 3-D Model Software Suite? Current Generation Nuclear Plants Physical Plant Plant Documentation Must Conform As-built information must be accurately reflected on plant documentation. Next Generation Nuclear Plants Physical Plant Must Conform 3-D Model Software Suite Must Conform Plant Documentation As-built information must be accurately entered into the 3-D Model Software Suite which then produces plant documentation. 10

11 What is a 3D Model? A 3-dimensional engineering tool for designing a plant 11

12 The configuration data is much more than a 3-D Model Sample Valve Attributes Tag number System Room number Data Sheet Assignment Body type Actuator type Pressure rating Material type Safety Class Size Actuator fail position Locking requirements Actuator electrical safety class Number and type of position indicators I&C system(s) that monitors valve position I&C system(s) that control valve position 12

13 Equipment Life Cycle Work Process Phase I: Equipment Data Development Phase II: Budget Estimate Phase III: Equipment Specs & RFQ Phase IV: Purchase Order / Vendor Drawings & Models Phase V: Fabricate /Deliver/Install Owner Operator Application Exchanges EPC Supplier / Distributor Conceptual Conceptual Design Design PerformanceReq Preliminary Preliminary Design Design BudgetRFQ Design Design Review Review Budget Budget Quote Quote Authorize Authorize Project Project Budget Estimate Authorization Authorization Estimate Estimate BudgetQuote Application Exchanges ProjectAuth Production Production Design Design BidRFQ BidDesign Bid Bid Package Package Design Review Design Review Bid Quote Bid Quote Phase Phase VI: VI: Operations Operations and and Maintenance Maintenance access access engineering engineering information information BidQuote Bid Bid Approval Approval BidReview Fab Fab Approval Approval Fab Fab Bid Eval & Review Review & Bid Eval & & Award Approval Award Approval Tagged List FabAuth Purchase Order Receive Receive PO PO POSpec Approval Approval Drawings Drawings FabDwg FabReview Fabricate Fabricate Ship Ship Invoice Invoice transaction As Installed Pay Pay PayRequest Receipt, Receipt, Inspection, Inspection, Installation Installation & & Commission Commission Care, Install + Spares AsShipped VendorDocs = AEX usage scenarios 13

14 Nuclear Information Handover 14

15 Business Strategy NEI / INPO Performance Model EPRI Programs Documents Data Flow INPO Programs Documents Data Flow DATA GOALS Timely Accurate Consistent Retrievability Re-usable Single Source STANDARDS - GOALS Open Standards Open Formats Open Architecture Primary Information/Data Categories 15

16 What Pieces Do We Have Now? IT tool availability is not the issue 16

17 What Pieces are Missing? An accepted and tested standard that defines: Use of reference data defining standard terms with precise meanings Accurate expression of relationships between data Retention and query of the full lifecycle history of the data Exchange of structured data in a standard format with a standard protocol Automatic collation from multiple external sources on demand Freedom from the need to identify, map and transform between applications 17

18 What is EPRI s Role? Provide and assemble the industry expertise to establish data interoperability standards for nuclear plant lifecycle management Provide the driving force to establish the nuclear industry standards Work with other organization (i.e. Fiatech) to capture and adapt existing expertise and standards Monitor adoption and provide support as needed 18

19 What are the Next Steps? Establish nuclear XML Schemas for critical components (Fiatech AEX) Harmonization of EPRI Initiative Actions/Results with ISO is Essential to the Effective Utilization of ISO for Achieving New Nuclear Virtual Power Plant Configuration Management in support of New Nuclear Power Plant Life Cycle Design, Operations, Maintenance and Engineering Quality Assurance Program for 2D and 3D Design and Modeling Software and V&V for Quality Software Develop XML Templates for Configuration Management Business Rules. 19

20 The Journey to Data Interoperability Join Us! 20