configuration management information system (cmis) using the

© 2015. Intergraph Corporation. All Rights Reserved © 2015. Intergraph Corporation. All Rights Reserved.

Configuration Management Information System (CMIS) using the PIM for the Power Industry. Opportunities, Challenges and Lessons Learnt

Kevin Gribbin June 2015

© 2015. Intergraph Corporation. All Rights Reserved

Topics

Intergraph Who are and What do we do

CMIS and PIM

PIM – “Current State”

Integration and Automation Opportunities

Handover – Turnover

PIM – “Future State”

Questions


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


Headquartered in Huntsville, Alabama

In business for 45 years

http://www.al.com/business/index.ssf/2014/10/post_195.html%23incart_river


PP&M Worldwide Representation

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


Intergraph Technology Portfolio

© 2015. Intergraph Corporation. All Rights Reserved 8

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

http://www.isa.org/


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.”


What is a CMIS?

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?

Configuration Management and Information System is an advanced plant information management system for nuclear power plants.

10


What is CMIS and who requires it?

6/23/2015

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 • Part 100 - Reactor site criteria

Institute of Nuclear Power Operations

(INPO)

AP929

“Configuration Control”

Institute of Nuclear Power

Operations (INPO)

INPO-09-00

“New Plant Configuration Management

Development & Implementation

Process”

• In many countries, regulatory authorities require a CMIS to obtain an operating permit.

• CMIS may include a document management capability, but a document management system is not a CMIS.

• CMIS principles being defined by the nuclear industry.

ANSI/NIRMA

CM-1.0 2000

“Configuration Management of

Nuclear Facilities”

IAEA

TecDoc 1335

“Configuration Management in Nuclear Power

Plants”

http://www.nrc.gov/reading-rm/doc-collections/cfr/

http://www.nrc.gov/reading-rm/doc-collections/cfr/part026/







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)


CMIS and PIM


Integrated CMIS Scope

14

CMIS Scope


Construction planning, mat’l mgt, and ITAAC tracking activities occur in Reference Design phase

Configuration Management: A Lifecycle Approach

CMIS ‘A’ CMIS ‘C’ CMIS ‘B’

Load Data & Documents from

Vendors, Contractors, etc

For Prime Contractor

Load Other Data &

Documents

For O/O

Inquiries & Commitments

with regulators, others

MCAD & Other

Tools

A/E or NSSS Vendor Reference Plant or Reactor Development

Prime Contractor Site Specific Project

Plant Operator Generating Plant System

Project Award

CM principles begin in design with effective change management and data correlation between disciplines

CMIS ‘A’ manages design basis, deliverables, tests & requirements

CMIS ‘B’ manages design basis, procured items, tests, commitments & requirements

CMIS ‘C’ manages design basis, assets/SSC’s; margin & requirements, In-Service Testing, operations support

Inquiries & Commitments

with owner, regulators, others

Turnover Data Load Handover

Load Other App

Data For A/E or NSSS

Project Turnover

ITAAC Tracking

ITAAC Tracking IST

Tracking

Tools


PIM

“Current State”


Typical Situation

Design Basis (SSC’s)

Change Management

Transmittals

Requirements Management

Inspection and Testing

Document Management

Configuration Management

Operations and Maintenance


Typical Situation – What is the Context


3rd party app

In-house app



Document Management

3rd party app


Why? What? When? Where? Who?


Typical Situation – What are the Risks


3rd party app

In-house app



Document Management

3rd party app


Incompatible Formats Data Duplication/Replication Poor Information Integrity Complex Change Management No Auditability/Traceability

• What/When/Who Geometric IT Cost Curve Upgrade Options



Document & Data

Management

Plant Structure

Management

Change Impact

Analysis & Management

Configuration Management

Project Management

& Collaboration

Intergraph Solution

Engineering Design Basis


Re-task and Re-Purpose

Composite Applets

Information Browsing

Document & Transmittals Management

Tag Management

Action & Issue Tracking

Project Execution

Project Management of Change

Interface Management

Non-Conformities Management

Technical / Site Queries

System Completions

Risk Reducing Measures

Composite Applets - continued…

Integrated Information Handover

Legacy Data Gathering (SmartPlant Fusion)

SPO Mobile Apps


Turnaround Planning – SPO R&D

Management of Operations Change

Inspection Assistant Building Information for Plant Maintenance Systems SPO R&D

Information Validation, Transformation & Loading (Smart Data Validator)


Installation Form X-Ray

Manufacturer Operating Parameters

Operational Check 2/1/03

Supporting Regulatory Compliance Controlling Plant Configurations

Dynamic Weld Inspection Data


Integration and Automation

Opportunities


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 2514-3, May 1987


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 $124,000 1.79x Valve Index $21,600 $167,600 7.76x Instrument Identification $17,800 $135,100 7.59x

Motor Index $15,200 $123,100 8.09x Piping Index $12,000 $84,400 7.03x Action Request $12,100 $44,200 3.65x Commitment Tracking $5,000 $14,900 2.98x

Circuit Breaker Index $5,000 $37,700 7.54x EPRI (Electric Power Research Institute) report NP-5159M, Research Project 2514-3, May 1987


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 2514-3, May 1987


Aggregation and Consolidation

Discipline Information

R&D Pump Duty: 1500m3/h Spec: AP610 Type: Centrifugal Location: Area B12

Engineering System: 27 (Potable Water) Function: Water Injection Tag No.: P-101 Materials: 25% Cr. Duplex Power: 550 kw Motor Tag: PM101

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

Discipline Information

Procurement Vendor: Sulzer Model No: 1173K74H Connections:16in Suction, 12in Discharge Weight: 11000kg Structure: Skid Seals: Crane BSTFN Power Supply: 11kv, 3ph, 60hz

Construction As Built: Dimensional data, Spool changes Test data: Inst. Records, pressure, Serial Number: 12993MN66

Controls Comm Records: Performance, NPSH Control Settings, Operating Limits Operating records: MTBF Performance curves

Operations IOM Procedures, QC Test: Hydro, String, Performance

Maintenance Equipment replacement & spares data, Lubrication and strip down records


‘Presentation’ Integration

Tiers of Integration

‘Data’ Integration

‘Application’ Integration

‘Business Process’ Integration

Valu

e to

the

busi

ness

Effort to Deploy

‘Integrated Composite Applet Implementation’

Consolidation

Access

Transport

Messaging

Leverage


Handover – Turnover

“What does this mean?”


EPC “where time TO market

is imperative”

Engineering data in Execution is stateful, volatile, temporal and spread across disparate sources and owners

Progress Management

Instrumentation Design

Project Management

Instrument Data Sheets

Process Simulation

Specifications & Standards

P&ID

Contracts

Mechanical Equipment

Design

Electrical Design

Line Lists

Valve Lists

GA’s and ISO’s

Civil & Structural

Cabling & Lighting

Hook up & Installation

Document Control

Project Portal

Time allocation & measurement

PFD

Automation & Control Design

Hazop

Requistioning

Equipment Data Sheets

Plant 3D Modeling

SLD’s & Schematitcs

HVAC

Procurement

Cost Controls

Equipment Lists

EDMS

Supplier Gateway

Shipping

Construction Sequencing

Test & Commissioning

planning logic connectivity layout actual completion


Process Control SPC

Recipe Work Order Execution

Engineering data in Operations spreads across multiple plant operational systems and time domains

ERP

Product / plant Lifecycle mgmt

EDMS

Specialty Quality Admin

Product Specs

Plant Centric

ERP

Formula Mgt Batch

Mgt

SCADA

SPC / Trends

Process Planning

Optimisation

Data Historian

MES

LIMS

FCP Factory Schedule

Automation Control Logic

Data Capture

Procurement

Financials

CRM

Trading Exchange

Supply Chain

Machine Logic

Process Mgt

Plant Operations

Production Schedule

Business Process

Supply Chain

Customer

Plant

Supply Chain

Extended Supply Chain

Process Automation

In Process Testing

Enterprise

Production Unit

Production Process

Machine

Reliability monitoring & optimization

Original diagram source courtesy: AMR Research

OO “where time IN market

is imperative”


Handover & Uploading

ERP

Product / plant Lifecycle mgmt

EDMS

Specialty Quality Admin

Product Specs

Plant Centric ERP

Formula Mgt Batch

Mgt

SCADA

SPC / Trends

Process Planning

Optimisation

Data Historian

MES

LIMS

FCP Factory Schedule

Automation Control Logic

Data Capture

Procurement

Financials

CRM

Trading Exchange

Supply Chain

Process Automation

In Process Testing

Reliability monitoring & optimization OO

Progress Management

Instrumentation Design

Project Management

Instrument Data Sheets

Process Simulation

Specifications & Standards

P&ID

Contracts

Mechanical Equipment

Design

Electrical Design

Line Lists

Valve Lists

GA’s and ISO’s

Civil & Structural

Cabling & Lighting

Hook up & Installation

Document Control

Project Portal

Time allocation & measurement

PFD

Automation & Control Design

Hazop

Requistioning

Equipment Data Sheets

Plant 3D Modeling

SLD’s & Schematitcs

HVAC

Procurement

Cost Controls

Equipment Lists

EDMS

Supplier Gateway

Shipping

Construction Sequencing

Test & Commissioning

EPC


PIM

“Future State”


Tag: P-101

Inter-Relationships across line-of-business systems

Des Op Press: 100psi

What we need at the functional location

Model: CP-C-4020

What can be obtained to fulfill the need

Des Op Press: 150psi

Manfr: Weir

What are its capabilities

Asset no: 24X89

What did we buy which is at the functional location

Supplier: Simmons

Who did we get it from

Purchase Order: U9735

Maint Proc: MM101

BOM: 24X89/P101

What do we need to maintain it

System: 20 – Separation

Plant: Texas2

What is the plant’s configuration

P&ID Drawing: C056-SA-P-XR-2032-01

Spec Document: C056-KIV-1-DS-2001

What documentation supports the licence and safety …and so on data sheet


Hierarchical VS Molecular

Most hierarchical Document Management systems model their information as represented by the familiar cabinet → folder → file paradigm.


Think instead of objects and relationships as molecular…


Management Communication

38 8/31/2011


View by Reason for Issue

39


SAFETY QUALITY PRODUCTIVITY


QUESTIONS!