extending the new plant design 3d model into an ... -...

Extending the New Plant Design 3D Model Into an Operations and Maintenance Tool

Ken BarrySenior Project Manager

2© 2010 Electric Power Research Institute, Inc. All rights reserved.

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)


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, 1997


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


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


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


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 2002.


What is Configuration Management (CM)?

PDPDPPPP

Engineering Design Basis per 10CFR50.2 “What needs to be there”

PlantDocumentation “What we say is there”

PhysicalPlant “What is actually there”

ConformConform

Conform

Work Processes must assure that:Elements conform all the timeAll changes are authorizedConformance is auditable

EDB


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


How is the CM process impacted by use of 3-D Model Software Suite?

Physical Plant 3-D Model Software Suite

Plant Documentation

Must Conform Must Conform

Next Generation Nuclear Plants

Physical Plant Plant Documentation

Must Conform

Current Generation Nuclear Plants

As-built information must be accurately reflected on plant documentation.

As-built information must be accurately entered into the 3-D Model Software Suite which then produces plant documentation.


What is a 3D Model?

A 3-dimensionalengineering toolfor designing aplant


The configuration data is much more than a 3-D Model

• 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

Sample Valve Attributes


PayRequest

Owner Operator

EPC

Conceptual

Design

Conceptual

Design

Design ReviewBudget Quote

Design ReviewBudget Quote

AuthorizationEstimate

AuthorizationEstimate

Authorize

Project

Authorize

Project

Design Review Bid Quote

Design Review Bid Quote

Bid ApprovalBid Approval

Fab Review &Approval

Fab Review &Approval

FabricateShip

Invoice

FabricateShip

Invoice

Receipt,Inspection,

Installation &Commission

Receipt,Inspection,

Installation &Commission

Fab ApprovalFab Approval PayPay

ApprovalDrawings

ApprovalDrawings

BidPackage

BidPackage

Bid Eval &Award

Bid Eval &Award

Receive POReceive PO

Phase VI: Operations and Maintenance

access engineering information

Phase VI: Operations and Maintenance

access engineering information

BudgetEstimate

ProjectAuth

BidDesign

BidReview

POSpec

FabDwg

FabReview

FabAuth

AsShippedVendorDocs

PerformanceReq

Purchase Order

As Installed

Phase I:Equipment Data

DevelopmentPhase II:

Budget Estimate

Phase III: Equipment Specs

& RFQ

Phase IV:Purchase Order /

Vendor Drawings & Models Phase V: Fabricate /Deliver/Install

BudgetRFQ

BudgetQuote

ApplicationExchanges

ApplicationExchanges

Preliminary Design

Preliminary Design

ProductionDesign

ProductionDesign

BidRFQBidQuoteSupplier /

Distributor

Care, Install + Spares

transaction = AEX usage scenarios

Tagged List

Equipment Life Cycle Work Process


Nuclear Information Handover


INPOProgramsDocumentsData Flow

EPRIProgramsDocumentsData Flow

STANDARDS - GOALSOpen StandardsOpen FormatsOpen Architecture

DATA GOALSTimelyAccurateConsistentRetrievabilityRe-usableSingle Source

Primary Information/Data Categories

NEI / INPOPerformance Model

Business Strategy


What Pieces Do We Have Now?

IT tool availabilityis not the issue


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


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


What are the Next Steps?

• Establish nuclear XML Schemas for critical components (Fiatech AEX)

• Harmonization of EPRI Initiative Actions/Results with ISO 15926 is Essential to the Effective Utilization of ISO 15926 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.


The Journey to Data Interoperability

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