Standards based Plant Lifecycle Management

ISO TC184/SC4 Meeting in Paris Engineering IT & VR solutions based on International Standards, PartDB Standards based Plant Lifecycle Management Industrial Day June, 2013 Dr. Jin Sang HWANG, PartDB Kyung Ik AN, PartDB Seung Hun LEE, KAIST Prof. Soonhung HAN, KAIST Dong Soo RYU, KHNP

Nuclear Plant R&D in PartDB Co., Ltd. Engineering IT & VR solutions based on International Standards! 1999 Gov. R&D Project (IMS VIPNET Project) Gov. R&D Project (Dev. Infra for Nuclear IT) 2003~2006 PartDB Spin-off APR Plus IMS Consulting 2005~2008 APR 1000 IMS Project 2009 2010 CAD & DEX Data EXchange consulting ISO 10303 STEP Knowledge Engineering Engineering DB & IT ISO 13584 / ISO 15926 Industrial Information Mngt. Enterprise IT Applications VR contents & platforms M&S ILS(including CBT & IETM) VR Sim. contents & platforms Gov. R&D Project (Dev. IMS for NPP) 2011 Member of Defense Venture Center ISO9001 2

PartDB s profile CEO JinSang HWANG, Ph.D Founded Address (H.Q.) Addr. (Branch O.) October, 1999 #205, IT Venture Town, 694, Taprip-dong, Yuseong-gu, Daejeon, Korea(305-510) #601, Vision tower, 52-3, Daechung-ri, Jangyou-myun, Gimhae, Gyeongsangnam-do, Korea. (621-831) Homepage Major Shareholder http://www.partdb.com Jinsang Hwang, Soonhung Han, et al. Several National Gov. Projects Nuclear - Pjt. Plant Lifecycle Management (w. KHNP) - Pjt. Configuration Management (w. KHNP, KINGS) Maritime & O.P. - Maritime Lifecycle Management (w. KR) - Eng. Information Publication for P.Q. (w. KR) - CBM, CM & DCS solution package (w. DSME) Eng. IT&DB Wind - Pjt. SCADA & CMS (w. KEPCO) - Pjt. Planning for CBM & EAM solution (w. KEPCO) CAD & DEX VR Defense -. (w. DTaQ, ADD) 3

Engineering IT & VR solutions based on International Standards, PartDB Korean Nuclear Power Plant Nuclear Fuel Pellet Nuclear Power Plant 4

Typical Lifecycle of NPP Start operation Cease operation Phase 1 Feasibility study & FEED Phase 2 EPCS Phase 3 O&M Phase 4 Decommissioning 1.1 Business Planning 2.1: Detailed Process Design 3.1: Licensing & Regulatory 4.1 Cold Operation 1.2 Option Generation 2.2: Detailed Engineering Design 3.2: Production Planning 4.2 Decommissioning 1.3: Project Planning 2.3: Procurement 3.3: Process Control & Monitoring 1.4: Project Definition 2.4: Construction & Pre-commissioning 3.4: Operating Procedures 1.5: Conceptual Process Engineering 2.5: Startup & Commissioning 3.5: On Demand & Preventative Maintenance 1.6: Conceptual Engineering Design 3.6: Site Engineering 3.7: Incoming & Site Materials 3.8: Outage Management 3.9: Revamp & Debottlenecking 3.10: Quality Control & Assurance 3.11 : Training * IAEA 5

The Focus of Nuclear Plant Lifecycle Management manage aging of Systems, Structures, and Components(SSCs); maintain an acceptable level of performance and safety; maximize ROI over the service life of the plant KHNP(Safety & Economic perspective) EPRI(Focused on Economic) Planning EPCS O&M Life Extension Decommission IAEA(Focused on Safety) IAEA : International Atomic Energy Agency EPRI : USA Electric Power Research 6 Institute ANSI : American National Standards Institute INPO : Institute of Nuclear Power Operations DOE : USA Department of Energy

CM Concept in nuclear power plant is a management discipline that applies technical and administrative direction to support lifecycle of an item for which configuration needs to be maintained Design Requirements Work processes must ensure that: Elements conform all of the time All changes are authorized Conformance is auditable Physical Configuration Facility Configuration Information * INPO 7

INPO AP-929 Configuration Control Process Description Configuration management process Evaluate identified problem or desired change Change Design Requirements? Change Change No No Physical Facility No Configuration Configuration Information?? Do nothing more Yes Yes Yes Design Requirements Change processes Physical Configuration Change Authorization processes Facility Configuration Information Change processes *IAEA-TECDOC-1335, Information Technology for Nuclear Power Plant Configuration Management, IAEA, 2010 8

Our Approach

We need consolidated information & well designed supporting system How to archive the goal? 10

Proposed Lifecycle Supporting Solution Lifecycle Activity* - Safety management - Asset management - Risk management and Decision making - Stakeholder management - Aging management - Preventive maintenance & Predictive maintenance - Quality management - Knowledge management - Performance management - Human resource management - Fuel cycle/waste management - License management - Periodic safety reviews - Economic optimization - Environmental management *IAEA-TECDOC-1335 **based on KURD (Korean Utility Requirement Document) 11 Supporting Solution** Information Integration & Consolidation Collaboration Environment Integrated Configuration Management Requirements management Change management Information management

To-be Engineering Environment Document Management Equipment management Resource Management Requirement Management Process management Communication /Reporting Configuration Management Collaboration Equipment Engineering Information Integration Instrumentation & Control Piping Design Civil Engineering Heat, Ventilation Air Condition Electrical Design 12

1 st. Model based information integration Document oriented communication Model based information integration A more fine granular information integration across domains and IT systems is required to follow up requirements more efficiently throughout the lifecycle, and enables multiple views of the product and efficient testing.

2 nd. Integrated Information -joined from different sources- Requirement Management Tools DOORS, etc Design & Engineering Procurement /Construction O&M -Process -Change & Approval -License Legacy System Integrated information helps decision making Overview of document, product and system information Possible to trace all issues and changes

The best from two standards ISO15926 for Engineering Data Reference data library Engineering data format P&ID/3D data exchange(draft) Requirement Management Configuration Management Product as realized O&M Information Consolidation PLCS: from requirement to decommisioning = Full Life-Cycle Support 15

PLIMS System Features Configuration Mgt. Identification Interface management Status accounting Configuration audit Margin control Baseline Plant design data Project data Document Spare part data Etc. Collaboration System Plant information Project information Document information Mapping & Consolidation Documenting Recording Monitoring Evaluating Reporting Change Proposals Approval Execution Change Notice Change Order Change Mgt. Change Agreement Impact analysis Information Mgt. Document control Role & effectivity Visualization Information mapping Single, unified data repository Resource control Condition management Schedule management Status control Transaction management Information packaging Data hand-over Requirement Mgt. Create/Update Requirement Requirement source Assignment to SSCs Tracing relationship Requirement verification Workflow Spare part information Etc. information 16

To-Be Environment Sub-constructors Engineering Project Procurement Requirement Technical data ETC Purpose Functionality Project mgt. Facility mgt. e-portal Role based Authentication PLIMS (Plant Lifecycle Information Management System) Configuration mgt. SSCs mgt. Engineering tools PLIMS Infra CM based Integrated Information Management Data Warehouse Application server e-portal Classification & structure Master information mgt. Technical data mgt. Requirement mgt. Configuration mgt. Process mgt. Access right mgt. Construction mgt. (NPCMS) PLIMS Standard protocol Master mgt. (PM/MM) PLIMS Supporting modules Standard Mapper Data hand-over template Import/Export Data packaging ERP (DREAMS) Technical data (LDM) 17

Benefit for the Owners & Operators Limit Operators costs for software licenses, updates & the staff qualification Ensure life-time maintainability of information independend from IT-tools Facilitate and accelerate data handover processes Robust, standards based and proven information foundation Long-term data archiving Integrated configuration management throughout the lifecycle Flexibility (Partners, Systems, Information scope, Process sup port) 18

Sample Screenshot UAE Requirement Tracing Change Management 19

Main Structure Information Panel Data Repository Work Area

Identification Information Related Documents Properties Related Req. Assigned Req. Packages Installed Equipment

Req. Req. Source

Req. Information Trace to Requirement is traced by Requirement

Component Req. List of Selected Component

P&ID Based Information Navigation Req. List of Selected Component Component

Thank You! 27

Other Screenshots 28

Selected Item Create Change Review Package Related Data with Selected Item 29

Requirement Structure Requirement Source Tracing Graphical UI

Req. Related Information Req. Information SKN 34 Req. Structure

Req Module: FS-SR210

Annex 33

Related standard data model ISO 10303-203 ISO 10303-214 ISO 10303-221 ISO 10303-227 ISO 10303-233 ISO 10303-239 ISO 15926 XMpLant CIMSteel IFC DWG, DWF, DGN X3D 34

Reference to develop the system ANSI/NIRMA INPO DOE IAEA EPRI IAEA : International Atomic Energy Agency EPRI : USA Electric Power Research Institute ANSI : American National Standards Institute INPO : Institute of Nuclear Power Operations DOE 35 : USA Department of Energy

Characteristics of Older Nuclear Power Plant Documentation is dispersed, even that containing very important information. The main design principles are not readily available. The original know-why is not readily available for use by plant personnel. Many plant changes have been made, But the cumulative effects of these ch anges have not been considered. After several years of plant operation, modification, and maintenance, mana gement of the plant does not have a high degree of assurance that the facilit y documentation reflects actual plant status. 36

Data Integration Issue System information Functional Location Design & engineering Business information PBS, FBS, ZBS Facility/Equip. Design document Part/Product Doc./DW Procurement & Construction Vendor document Material & datasheet Attributes 3D Model Activity O&M O&M information O&M data 37

Collaboration Issues between partners & suppliers Data exchange between consortium partners, architect engineers, key engineering contractors Data exchange between equipment suppliers (component data, operation & maintenance) between projects Modularization of plant and Engineering re-use Information/ Configuration Management across plants between EPC & O/O Handover of virtual plant into Owners system Consider Owner/ Operators need for operation and maintenance Consider plant life time (80 years) data maintainability between tools Data management & configuration management between the modules of the IMS Interfacing ERP, EDM, PMS, and design tools of specific disciplines 38

Involved Standards & Guidelines ISO-10007, ANSI-NIRMA, CMII, DOE-STD-1073, etc. Management activity standards(systems engineering, Quality, Configuration, etc.) Concept terminology Content terminology Processes/Activities Infrastructure standards Basic modeling standards Product definition Product specification Classification Identification IAEA, EPRI, INPO, NEI, etc. ISO 10303-239 ISO 15926 STEP, IFC, W3C, etc. XMpLant, DXF/DWG 39

High level system architecture Requirement (DBD) Engineering (2D/3D/Data, etc.) Suppliers data (Spec./Model) Construction data AS-Built Data O&M Data PLIMS FUNCTIONALITY Configura)on management Informa)on integra)on Consolida)on Change management Requirements management Collabora)on Repor)ng Standards based data storage and exchange, ISO 10303-239 and ISO 15926 Integrated GUI(2D/3D ) NPCMS(Construction Mgt.) LDM(Filevault) OMS(O&M) 40

Requirement Management for New Nuclear Power Plant Nuclear & Civil Law 10 CFR KURD Code & Standard Contract Regulatory Guideline Requirement Source Validation Requirement O & M Requirement Acceptance Test Operation & Maintenance Operation Procedure Operating Experience Maintenance Manual Maintenance History QA Plan NSSS Design Bases Design Criteria Manual Design Bases System Requirement System Design Criteria System Functional Description Calculation/Analysis Report Design Parameter 2D CAD/Drawings System Requirements Test & Operation Requirement System Test ITAAC(Inspection, Test, Analysis and Acceptance Criteria) Test Procedure Guideline/Operation Procedure Guideline Test Procedure/Operation Procedure Test Result Evaluation Safety Analysis Report Interface Requirement Interface Requirements Design Specification Technical Specification Data Sheet 2D & 3D CAD/Drawings Component Requirements Test & Operation Requirement Component Test ITAAC Test Procedure Guideline Test Procedure Test Result Evaluation Inspection & Test Requirement Inspection & Test Requirement Purchase Order Procurement Manufacturing Construction Inspection Plan Inspection Report Manufacturing DWG Inspection Plan Inspection Result 41

Requirement [SR_RCS_0150] Relation Nuclear & Civil Law 10 CFR [CONT_0068] KURD Contract Code & Standard Contract Regulatory Guideline Requirement Source Validation Requirement O & M Requirement Acceptance Test Operation & Maintenance Operation Procedure Operating Experience Maintenance Manual Maintenance History QA Plan [NDB_0099] NSSS Design Bases NSSS Design Criteria Bases Manual Design Bases System Requirement System Design Criteria [SR_RCS_0150] System Functional Description SR Calculation/Analysis FOR RCS Report Design Parameter 2D CAD/Drawings System Requirements Test & Operation Requirement System Test ITAAC(Inspection, Test, Analysis and Acceptance Criteria) Test Procedure Guideline/Operation Procedure Guideline Test Procedure/Operation Procedure Test Result Evaluation Safety Analysis Report Interface Requirement Interface Requirements Design Specification [DS_RVA_0001] Technical Specification DS FOR RV ASSEMBLY Data Sheet 2D & 3D CAD/Drawings Component Requirements Test & Operation Requirement Component Test ITAAC Test Procedure Guideline Test Procedure Test Result Evaluation Inspection & Test Requirement Inspection & Test Requirement Purchase Order Procurement Manufacturing Construction Inspection Plan Inspection Report [2511-431-M-RV01] Functional Location of RVA Manufacturing DWG Inspection Plan Inspection Result 42

Relationship between various configuration information Documents/Contents Requirements & Specifications Functional Requirements SSCs List Schematics Closed-loop System and Functional Components 3D model & Interfaces Size, Appearance and Overall Arrangement Configuration Audit Process Views How Produced, Used & Maintained /Change controls Record Management 43

Future Plans SKN #7 NPP Construction Start 12.06 13.06 14.06 15.06 16.06 17.06 1 st Year 2nd Year 3rd Year 4th Year 5th Year Develop R&D Plan Pilot Test Plant Life Cycle Mgt. System Global Collaboration Portal Configuration Mgt. of NPP PLIMS Verification & Validation Future R&D Plan Step II R&D(O&M) 44