system engineering and configuration management in iter presented by stefano chiocchio iter jws...
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System Engineering and System Engineering and Configuration Management Configuration Management
in ITERin ITER
Presented by Stefano Chiocchio ITER JWS
Pietro Barabaschi, Hans-Werner Bartels, Stefano Chiocchio, John How, Akko Maas, Eric Martin, Bill Spears, Eisuke Tada
System Engineering and Configuration Management
The ITER Challenges
Configuration management elements and tools in ITER
Conclusions
SynopsisSynopsis
System engineeringSystem engineering
The realization of large civil and industrial construction works,the management of large interconnected systems, big science endeavors, require that
different engineering disciplines and specialized design groups are organised and their efforts converge to the achievement of the common goal.
The scope of the SE is to:
• establish the requirements and physical architecture of the project,
• manage its development from conceptual to detailed definition, and
• assess and control its performance.
Relationship between System Engineering and Relationship between System Engineering and configuration managementconfiguration management
Configuration managementConfiguration management
The scope of configuration management (CM) is to ensure that:
accurate information consistent with the physical and operational characteristics of the project is available at any point of time.
The ability to rapidly identify and retrieve this information is vital:
• to ensure that all participants to the design activity use consistent information,
• to assess the implication of design changes during the design and construction,
• to manage the assembly and installation operations,
• to plan for the maintenance operations
• to be able to react to unexpected or emergency situations,
• to support future upgrades,
• to safely manage the decommissioning phase.
Basic relationship in Config. ManagementBasic relationship in Config. Management
SE and CM during the ITER design and construction SE and CM during the ITER design and construction processprocess
Time Bar
Conceptual design
Component design
Functional design
Overall architect
ure
Component Procurement &
installation
SystemsIntegrat
ion
Operation
Detailed
design defi
nition
Inte
grate
d desig
n definiti
on
Objectives definition
Parameters selection
Requirements management
Definition of config (envelope) models
Digital mock-up Clash detection
Requirement v
performance check
config control & assembly
Conceptual definition
Detailed design Procurement phase
Value engineering Change (non conformity) control
Concurrent engineering
The ITER challenges: The ITER challenges: The Scientific The Scientific MissionMission
The Physics parameters are strongly linked to design choices It is a First of a Kind Plant many specialistic skills are required but even more difficult is to find people with a wide knowledge
of the entire plant
The ITER challenges: The ITER challenges: The TechnologyThe Technology
The tokamak assembly very highly integrated design, small clearances, large number of parts (few millions), few components using well proven
fabrication technology.
The tokamak building many systems, equally important for the mission of
the project, not spatially separated, with many functional interfaces.
Unusual operational conditions (nuclear, vacuum, cryogenic, magnetic) and processes (e.g. heavy items handling, remote maintenance,etc)
The ITER challenges: The ITER challenges: The Project The Project OrganisationOrganisation
International collaboration, multi-cultural environment Distributed design activities Communications Concurrent engineering Procurement scheme
EU
China
USA
India
RF
JapanS Korea
Configuration Management Elements in Configuration Management Elements in ITERITER
Management of requirementsManagement of requirements
Identification of the configurationIdentification of the configuration
Document and project data controlDocument and project data control
Change controlChange control
Management of interfacesManagement of interfaces
Risk ManagementRisk Management
Management of requirementsManagement of requirementsThe Plant Design Specification defines the externally imposed essentially and design indepedent requirements of ITER
The Project Integration Document describes:
1) elements of Project Management
2) overall machine configuration, basic parameters, configuration tables and operation states,
3) general requirements, parameters, loads and interfaces grouped by broad subjects
4) main configuration of each system
The DRG2 (Design Requirements and Guidelines level 2)
covers all specific requirements for each system
This is responsibility of the WBS RO
The Plant Break-down Structure The Plant Break-down Structure and the ITER Digital mock-upand the ITER Digital mock-up
All systems and parts of the ITER project are organised around a tree structure called PBS (Plant Breakdown structure)
Drawings , Documents, procurement and operational data can be accessed by navigating this structure.
The management of the 3D models representing the plan is done throuh ENOVIA, (a sotware by Dassault Systemes for the management of the Virtual Product Data)
The data stored in Enovia can be accessed by all members of the design team either by active connection or in passive modes using a web based client application . The parts can be visualised, reviewed and relevant information can be retrieved.
• Open Source Software (Zope)
• ITER Owned and Managed
• Use through Internet Browser http://www.iter.org/idm
• Powerful search capability
• Easy (intuitive) use
• Integrated workflow with:
– Signing, approval (electronic signature)
– Comments
– Versions
• Security settings allowing read/write access to be set by users
• Online and printed users manuals, online bug and feature request forms
http://www.iter.org/idm
The ITER Documents Management System The ITER Documents Management System (IDM)(IDM)
Available for ITER Staff, Partners and Collaborators
Generic User name and Password
•http://www.iter.org Public Web
•http://www.iter.org/bl Technical Baseline Web
•http://www.iter.org/cad PDF Drawing library (Passworded for ITER and Collaborators)
•http://www.iter.org/idm ITER Document Management vault (Passworded)
•http://www.iter.org/team Internal ITER Team web (IP and Password protection)
Management of Information: Management of Information: The ITER Tech web siteThe ITER Tech web site
The ITER design change processThe ITER design change process
Every “proposed” design change is assessed at the system level, first...:
• Integration issues (management of the interfaces)
• Impacts on overall performance
• Impacts on cost
• Consistency between requirements and design concept
• Consistency between design concept and the actual design of each part (at this stage the CAD model of it later the real part)
... and then at machine level:
... and if approved by the Technical Coordination meeting a Design Change Request is issued and a number is assigned to it.
Management of Design ChangesManagement of Design Changes
ITER Interfaces Management ProcessITER Interfaces Management Process•Interface identification
•Identify the interfacing systems, and type of interfaces (geometrical, functional, importance)
•Interface initial description by cognizant part•The most affected user have the first go
•Interface reviews•This is done in parallel to the design reviews of the affected components
•Assessment of the assembly and maintenance implications
•Together with design review of each system•Creation of Interface description documents
•These documents are integral part of the technical documentation of the procurement specs.
•Definition of the interface ownership and interface monitoring
•A clear identification of the responsibility is critical.
The ITER Interfaces MatrixThe ITER Interfaces Matrix
•
Colour coding:
partner interface X
normal interface X
complex interface X
very complex interface X
Risks/opportunities management:Risks/opportunities management: Issues Issues IdentificationIdentification
We started this process end of 2004 with a set of broad scope Design reviews, to initiate a critical review of the status of the design and to organise the further work.
The issues cards have been reviewed and prioritized with the IT leader and since then at Technical coordination meetings
Issues can be raised by all People involved in the ITER activities (ITER ORG and ITER PTs/DAs members.
The issue are classified according to the WBS structure and the Responsible officer of that activity become the issue RO.
About 260 Issue cards have been proposed so far and stored in a database.
Risks/opportunities management:Risks/opportunities management: Issues Issues databasedatabase
The database of all issues are available on the web
Help and explanation are provided by S.Chiocchio and C. Capuano.
Button to add a new
issue
Issue summary by status
Button to start a search
www.iter.org/tech
The database provides summary of the issues by status and by role of the user,Search functions and possibility to add new issues
Probability (the likelihood of risk occurrence)
High (3) = Very Likely More than 90%
Moderate (2) = Likely more than 10% to 90%
Low (1) = Not Likely up to 10 %
Time ( time to start action or mitigation)
Near Term (N) = <3 months
Mid Term (M) = 3 months to 1 year
Far Term (F) = >1 year
Risks/Opportunities AnalysisRisks/Opportunities Analysis
Risks/Opportunities AnalysisRisks/Opportunities Analysis
Risk type High (3) Very likely > 10%
Moderate (2) Likely >10% up to 90%
Low (1) Unlikely > 90%
1
3
Likelihood
Co
ns
eq
ue
nc
e
21
2
3
Low (1) Moderate (2) High (3)
Technical minor modifications required
Some adjustments to baseline required
Descope, or extensive workaround required
Cost less than 1kIUA between 1 and 10 kIUA
above 10 kIUA
Schedule
impact
+week >1month
< 6 months
> 6months
High: implement new process or change baseline
Medium: Aggressively manage considerr alternative process
Low: Monitor
ConclusionsConclusions
• During the ITER Transitional Activities (starting in 2001) a large effort and dedication has been spent to ensure that appropriate procedures and tools for the technical management of the project are deployed at the start of the ITER construction.
• Thanks to the commitment of the few people involved, we have succeeded:– in reviewing the present working practices,– clarify and envisage future needs, – assess different tools available and in use on the markets^,– test and deploy the new software,– and introduce procedure for the management of designc hange and document management.
• The systematic approach that we have developed and applied and the tools that we have been using compare favourably with those in use in similar large projects.
• further effort is neededto be done to:– a) to adapt the tools to the new process that the ITER team has to manage, and – b) to fully deploy these tools also to the participant teams– c) to apply consistently the interfaces and risk tracking procedures .
• We believe that this will enable the ITER organization to manage the challenging task ahead.