extending the new plant design 3d model into an ... -...
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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)
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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
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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
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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
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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
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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.
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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
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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
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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.
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What is a 3D Model?
A 3-dimensionalengineering toolfor designing aplant
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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
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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
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Nuclear Information Handover
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INPOProgramsDocumentsData Flow
EPRIProgramsDocumentsData Flow
STANDARDS - GOALSOpen StandardsOpen FormatsOpen Architecture
DATA GOALSTimelyAccurateConsistentRetrievabilityRe-usableSingle Source
Primary Information/Data Categories
NEI / INPOPerformance Model
Business Strategy
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What Pieces Do We Have Now?
IT tool availabilityis not the issue
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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
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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
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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.
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