Nuclear Configuration Management Technology Solutions

1. Nuclear Configuration Management Technology Solutions Kent Freeland Vanya Yordanova WorleyParsons Europe Energy Services RISK Engineering Ltd. June 30, 2009

2. Overview • Nuclear Power Renaissance: New Attention to Nuclear Safety, Engineering and Business Efficiency • Information and Process Technology has significantly evolved since 1980’s, and more fully integrate CM with existing processes. • New Industry Profile for Configuration Management and Asset Management. • Enterprise-level IT Solutions that support Nuclear Business Model, MRO and Configuration Management requirements. • Technology comparison: PLM vs. legacy Repository-based • New factors in the “Buy/Build” Decision Tree • Sample Development of PLM-based Nuclear Power Technology Solution • Integration of Legacy Data Management and Outboard Applications

3. Types of NPP IT Solutions for CM Departmental Systems (VBNET, Archimed, etc.) Enterprise NPP Maintenance Resource Optimization (MRO) or “CM” system – Technical CM Control Enterprise Resource Planning (ERP) system (SAP, Oracle, Internal) – Financial CM Control

4. Nuclear Power Renaissance • New Attention to Nuclear Safety, Engineering and Business Efficiency • Better understanding of Configuration Management and the elements that create CM, including: • Design Basis Management • Nuclear Knowledge Management • Plant Lifecycle and MRO • Asset Management • Plant Life Extension • Nuclear Business Processes • These functions are often regarded as nuclear business processes, with Configuration Management a collateral benefit. • Actually, The converse is true: Configuration Management is the principal means to support and facilitate these functions.

5. Nuclear Business Functions

6. Technology EvolutionInformation and Process Technology has significantly evolved since 1980’s, and more fully integrates CM with existing processes. 1980’s – 1990’s • Centralized computing on expensive, enterprise-based Mainframe or large Departmental computers and hardware. • Expensive, resource-intensive operating systems and complex 2nd/3rd -generation programming languages. • Large, complex and proprietary Relational-design databases with limited choice of design tools and fast obsolescence. • Limited GUI Choices • Processes and business rules are indelibly coded into the software, and are difficult to adapt to individual NPP work processes, procedures and culture. • No Internet • Nearly impossible to achieve true Nuclear Configuration Management with these technologies • Commercial Nuclear CM and MRO applications during this era are resource-intensive, unpopular and astronomically priced. • Internally-developed systems are maintenance-intensive and resist change or update.

7. Technology Evolution 2009 • De-centralized computing, or low-priced IP networks based on server-router and LAN/WAN architecture. • Massive increases in computing power with simultaneous drop in cost. • Order-of-magnitude decrease in hardware and infrastructure costs. • Availability of inexpensive, or even free, operating systems and simple, open-source 4th/5th -generation programming environments and process modeling environments (such as JAVA and IDE). • Alternatives to monolithic Relational databases and query facilities in the form of SQL, XML and network-based database technologies. • Popularization of HTML and IP-based interface environments (.NET, .ASP, etc.) • New software designs that permit users to easily tailor the baseline system functionality to fit their job requirements and culture. • Universal Internet access • New Commercial Nuclear CM and MRO applications utilizing PLM and IDE Modeling technologies are under development. • Internally-developed systems are far easier to develop and maintain, but the requirement for the utility or plant to understand Nuclear Business, MRO and Configuration Management is unchanged.

8. New Industry Profile for Configuration Management and Asset Management in 2009 • Today, the Nuclear Power Industry understands the goals and requirements for effective CM better than ever. • Configuration Management is now better recognized as a key element in overall NPP safety and viability. • The lessons of neglecting Configuration Management are now well-known, including plant operating incidents, poor INPO performance, forced plant shutdowns and expensive Design Basis Reconstitution projects. • The role of CM in collateral benefits of plant safety, financial performance, regulator confidence, personnel management and knowledge base, and general efficiency are better appreciated than in years past. • Recognition of a strategic direction for plant operating management and lifecycle control is appearing in operating plants, and for planning and construction of new builds. • Past NPP IT solutions have provided experience useful in evaluating new technology and solutions available today.

9. IT Solutions that support Nuclear Business Models Nuclear Operations, Engineering and Maintenance require IT solutions that perform the following: • Track and manage the business processes to operate the NPP, such as Maintenance, Engineering, Parts and Warehouse, Operations and Purchasing/Procurement. • Manage the processes for design basis and basic NPP configuration, such as Master Equipment List, Document Review and Control, and Engineering Design Changes and Procurement Engineering. • Provide for Requirements Management, to support Licensing, Engineering, Maintenance and Action Tracking requirements. • Provide and support an infrastructure to coordinate, collaborate and communicate plant events and changes instantly to all concerned organizations. • Support “3-D” Computer Aided Design (CAD) for utilization in engineering, plant modeling, component identification, and to support paperless design. • Provide a means to support long-term analysis of plant and component asset condition and performance over life, providing both Repair/Replace/RTF maintenance support and plant life extension. • Furnish the means to identify, collect and provide access to critical plant implicit and explicit knowledge to be captured as staff and vendors turn over.

10. Technology Comparison: PLM vs. legacy Repository-based Traditional “Repository”-based System Architecture Primarily COLLECTSData for later Retrieval, Analysis, Reporting or Archive. You must know what you need to retrieve information You must know that you need to retrieve it NOW. “Plant Lifecycle Management (PLM)”-based System Architecture Primarily MOVES Data and Events for immediate application to CM-, Knowledge- or Asset-based tasks Appropriate information is delivered to you when you need it.

11. New factors in the “Buy/Build” Decision Tree • Approaches • Develop and program the NPP Nuclear IT solution 100% in-house, to be deployed on the selected target architecture. • Purchase and deploy a turnkey IT MRO solution, which may include an integrated ERP host architecture migration (such as SAP or Oracle-based products). • Design and deploy a hybrid solution of in-house and commercial IT elements.

12. Sample Development of PLM-based Nuclear Power Technology Solution Preparation • Goal is: development of a Nuclear Power Generation enterprise technology solution for NPP configuration management, asset management, and possibly design and construction systems. • Establish a comprehensive nuclear power generation Configuration Management, Asset Management and functionality model to support system review/development. • Use PLM for a type of “Instant Messaging” Configuration Management – notifies all affected system users of change in process or plant configuration the instant it occurs. • With 3-D Modelingtechnology, the solution should support the creation of a closed, integrated CAD-to-Control Room system for end-to-end design control, as well as 3-D plant model to facilitate design changes and identify components. • The NPP should explore all alternatives, including new technologies and solutions as legacy nuclear business technology solutions currently on the market, combined with CM-based processes and configuration control features needed to implement a Nuclear Configuration Management solution. • Selected solution should match NPP IT Target Architecture to avoid undue burden on infrastructure and existing systems.

13. Sample Development of PLM-based Nuclear Power Technology Solution Architecture and Design Features • Reduce complexity, interface and ergonomic issues traditionally associated with cumbersome legacy, manual or rogue IT systems at NPP’s by following the legacy and data development model (later in presentation). • Look for advanced, 4th/5th generation software architecture and technology, preferably utilizing a discrete process modeling environment (IDE), to capture business rules and transaction processing with little or no software programming. Then, nuclear business functionality stays persistent through systems software updates, versions and changes. • System should accommodate an integrated ERP hub interface; this may be for SAP, Oracle or custom utility-based system (which most are). • A self-documenting design platform is preferred; there should be little or no need for SDK’s and screen forms generators. Today’s IT organizations want to rely far less, if at all, on outside software development and consulting. • Users will be attracted to an interface that utilizes XML/HTML and offers a “web page” look-and-feel. • The product should be as modular as possible, along NPP functional lines, to facilitate deployment timeliness or phased implementation.

14. Sample Development of PLM-based Nuclear Power Technology Solution PLM replaces often ambiguous MRO system links and interfaces with a single point of contact for Configuration Management and Design Control.

15. Integration of Legacy Data Management and Outboard Applications Data is created, reviewed and approved over a prescribed content review lifecycle that ensures the Configuration Management Integrity of the content. The process may be divided into three “tiers” or levels, from the creation of the data or document, through the review and approval of content and subsequent delivery to the enterprise CM/MRO system.

16. Integration of Legacy Data Management and Outboard Applications • Systems Integration • Data should be integrated and managed based on a CAD-to-Field architecture. Legacy data, such as engineering databases, CAD data, preliminary design and EPC data (for new builds or design changes) should follow a path similar to that shown below. This creates a lifecycle from creation to quality records where the development of the document/data is traceable and has value as a CM tool. • Systems integration not only addresses core plant business functions (vertical integration), but those NPP business areas that supply data, documents and other objects to the CM system (horizontal or flat integration). The design engineering area demonstrates a particularly strong impact from CADD sources, raw design data repositories, data and specification sheets, and niche data sources from industry and trade groups, which produce basic NPP documents and quality records. The data repository and post-CAD data are of particular interest to design and construction organizations, which follow a cohesive data- and document-creation and distribution taxonomy that cannot be effectively followed without a PLM-type facility.

17. Questions?