Configuration Management
Publications at IAEA
Presented By:
Kent Freeland
WorleyParsons
1
IAEA CM GUIDANCE
DOCUMENTS
The IAEA has been active at
providing CM guidance to nuclear
entities outside of the USA. In 2010
the Agency issued two new CM
documents: Safety Series Report 65,
“Application of Configuration
Management in Nuclear Power
Plants” and TECDOC-1651,
“Information Technology for Nuclear
Power Plant Configuration
Management.” This presentation will
provide an overview of these
documents and establish the linkage
to current USA CM guidance.
NPP Version 1.0
Design Package 11-00001
NPP Version 2.0
2
IAEA and CM
•
The International Atomic Energy Agency (IAEA) is part of the United
Nations Organizations (UNO) located in Vienna, Austria.
•
The Agency originally established the Configuration Management
program within the Nuclear Engineering (NE) Department. The
responsibility was split between NE and Nuclear Safety.
•
Currently, the majority of the CM activity has been transferred to the
IAEA Nuclear Safety (NS) Department.
•
IAEA Publications have several classifications, such as Technical
Documents (TECDOC) and Reports . Official IAEA publications can
take anywhere from 1-3 years to develop from concept to publication.
•
This lifecycle can create some risk of obsolescence.
•
The Agency recognizes the importance of CM for NPP’s and includes
CM Requirements in their new build requirements for Member States.
3
Current IAEA CM Publications
• Most IAEA publications were co-authored or
primarily written by CMBG members.
• There are normally a number of Member State
reviewers who review and comment on the draft
documents
• The two latest were principally written by Kent
Freeland, Rick Harris and Cliff Wallen, all CMBG
attendees.
4
TECDOC-1651
“Information Technology for Nuclear Power Plant Configuration
Management.”
5
TECDOC-1651
“Information Technology for Nuclear Power Plant Configuration
Management.”
•
TECDOC-1651 was largely written by Kent Freeland and Cliff Wallen,
with the work split between Information Technology and Design Basis.
•
The document was then reviewed and edited by Kent and Cliff to
cross check content, and published in March of 2010.
•
The document is a new concept, and does not replace any existing
IAEA publication. It completes the Configuration Management trilogy
of CM Requirements, Technology Impact on NPP Document
Management Systems (TECDOC-1284 by Dr. Ki-Sig Kang of IAEA))
and Implementation and NPP Information Technology.
•
The document address NPP MRO and ERP requirements in general,
with emphasis on CM and related programs.
6
TECDOC-1651
“Information Technology for Nuclear Power Plant Configuration
Management.”
• Title
“Information Technology for Nuclear Power
Plant Configuration Management”
• Requested by: Nuclear Engineering Department
• Sponsor:
Jiri Mandula
• Authors: B. Grimes, K. Freeland, C. Wallen
• Supersedes/Replaces: N/A
• Applies to: NPP’s during design, construction and operation
• Commenced: October 2008
• Published: March 2011
• Available from: IAEA Publications website
http://www-pub.iaea.org/MTCD/publications/PDF/te_1651_web.pdf
7
TECDOC-1651
“Information Technology for Nuclear Power Plant Configuration
Management.”
General Purpose
•
Describe the requirements of forming and maintaining an NPP design
basis, and conducting a design basis reconstitution if necessary.
•
Describe and outline the requirements for NPP enterprise configuration
management information technology solution to store and maintain the
design basis and other NPP configuration management data.
•
Includes development of supporting MRO, ERP and Knowledge-based
functionality for enterprise nuclear business processes and business
rules.
•
The TECDOC includes examples of enterprise NPP CM solution
architecture, functionality, interfaces and data models.
•
Also compares the advantages of repository- and PLM (Plant Lifecycle
Management)-based solutions.
8
TECDOC-1651
“Information Technology for Nuclear Power Plant Configuration
Management.”
Suggested Utilization
The TECDOC should be reviewed and referenced during the review of
design basis programs and to assess the state of the NPP design basis
library and engineering change control system.
It is also recommended as a checklist for design basis review during
engineering change control and modification activities.
The document is recommended as a handbook for preparation of
specifications, RFQ’s and purchasing bid media for development or
purchases of enterprise CM, MRO and ERP software solutions
The document also aids in selection of supporting applications such
as engineering design and 3D CAD environments, document
management applications, content management and IMS support
systems and other 1st- and 2nd-tier software.
9
Safety Series Report No. 65
“Application of Configuration Management in Nuclear Power Plants”
10
Safety Series Report No. 65
“Application of Configuration Management in Nuclear Power Plants”
• Originally designated as publication 1461, was
largely written by Rick Harris of CMBG.
• It was reviewed and edited by Kent Freeland, and
published in January of 2010.
• Replaced the venerable TECDOC-1335,
“Configuration Management in Nuclear Power
Plants”, originally published in 2003 and considered
a benchmark for CM references.
11
Safety Series Report No. 65
“Application of Configuration Management in Nuclear Power Plants”
Safety Series Report No. 65
Title: “Application of Configuration Management in
Nuclear Power Plants”
Requested by: Nuclear Safety Department
Sponsor: Csila Toth
Authors: R. Harris, K. Freeland
Supersedes/Replaces: TECDOC-1335
Applies to: NPP’s and Nuclear Facilities during design,
construction and operation
Commenced: Summer 2008
Published:
January 2011
Available from: IAEA Publications website
http://www-pub.iaea.org/MTCD/publications/PDF/Pub1461_web.pdf
12
Safety Series Report No. 65
“Application of Configuration Management in Nuclear Power Plants”
General Purpose
Describe the requirements and business processes in NPP’s
to develop and implement a comprehensive configuration
management program, processes and procedures.
Includes premise, requirements, processes and resources to
establish and maintain a CM program for NPP’s.
Replaces TECDOC-1335, “Configuration Management for
Nuclear Power Plants”, published in 2003.
13
Safety Series Report No. 65
“Application of Configuration Management in Nuclear Power Plants”
Suggested Utilization
This Safety Series Report was published in the new IAEA
Report Format, in compliance with the new four-tier
document hierarchy structure.
This document should be reviewed and referenced during
development and when writing process plans and procedures
for NPP CM implementation, review, STAR Assessment or
Audit.
May also be utilized to assess contractor and vendor/supplier
CM programs and related taxonomies.
14
Overview
15
Elements for CM

Review and Assessment of overall NPP Configuration management and
IMS needs

Review and Plan for Design and Construction Requirements, or Legacy
NPP Operation

Review of current IT architecture and Nuclear Management Systems
infrastructure

Nuclear Business Processes Review, with emphasis on:
–
Master Equipment List (MEL) Registration and Taxonomy
–
Document and Records Management (RM/DC) facilities
–
Engineering Design Control and Design Basis Management
–
plus Materials and Work Management interfaces to support CM.

Propose CM and IMS Methodology to Implement Full-Scope Templatebased CM and IMS systems

Design for End-to-End CM Data Flow – Creation, Review/Verification,
Publication

Custom-Match and Employ a Graded Approach to Adjust Level of Detail to
NPP Technology and Safety/Risk function of components.


Develop Custom Baseline CM Process and Procedures for NPP
Assist in selection or development of modern, metadata-based
Departmental and Enterprise IT solutions to fit NPP IT architecture and
needs

Assist in development of CM Information Technology, Data and Process
Management processes.

Support and Integrate CM with existing or planned NPP Nuclear
Knowledge Management (NKM) and Integrated Management System (IMS)
programs





Processes
Processes and
and Templates
Templates using
using IAEA
IAEA GSGS- RR- 33
ThreeTier
Data
Management
Architecture
Three- Tier Data Management Architecture
Integrate
Integrate with
with IMS
IMS program
program to
to support
support CM
CM
Plant
Plant Lifecycle
Lifecycle Management
Management (PLM)
(PLM) Principals
Principals
Integrated
Integrated Management
Management System
System (IMS)
(IMS) –– Proactive
Proactive
Framework
Framework for
for FullFull- Scope
Scope ISO
ISO 9001/
9001/ 14001Quality
14001Quality
Management
Systems
endorsed
by
IAEA,
Management Systems endorsed by IAEA, EPRI
EPRI and
and
INPO
INPO
16
Design Requirements, Design Basis – and Design Responsibility

The NPP Design is developed, recorded and managed
from the first day of NPP design.

Design Requirements come from NSSS Vendor, State
Regulator, NGO’s and other sources.

The ability to preserve, manage and apply these design
requirements and form a design basis for the NPP is
the cornerstone of NPP Safety.

As the plant is changed, the recorded design basis
must change also to preserve the overall design and
establish or adjust operating margins.
Without a Design Basis,
Everybody forgets “Why was
this change made?
Every Design Change has a
documented package
showing what was changed
and why.
NPPVersion
Version1.0
1.0
NPP
Design Package 11-00001
Design Package 11-00001
NPPVersion
Version2.0
2.0
NPP
17
Elements of Design Requirements

NPP Design Basis History – what was changed in the NPP,
and how it will behave now

Margin Analysis and Management – The distance between
normal operation and failure of a component

Technical Specifications (TS) – Parameters and conditions
under which safe NPP operation may continue, even at a
reduced level




Warehouse,
Handling, Issue
& Return
Beyond Design Events – Ensuring consideration of mitigation
for those NPP events considered beyond anticipated normal
design basis accidents.
Safe Shutdown – the ability to stop the plant and secure the
reactor in a way to not present any harm to the public.
Design
DesignVerification/Walkdown
Verification/Walkdown
PLM Roles and Controls
for Procurement and
Materials Qualification
Component
ComponentQualification/QA
Qualification/QA
Materials
Receipt
Procurement
Manufacturer/Supplier
Manufacturer/SupplierQAQA
Plant Design Basis
Engineering Design
Change
Physical Plant
Equipment
Plant Documentation
Document Control
and Quality Records
Master Equipment
List (MEL)
Equipment
Documents
& Records
Radiation
Protection
Material &
Inventory
Engineering
Change
Bill of
Material
DATA HUB
Project &
Financials
Purchasing
All of these factors affect the
ability to keep the NPP safe
during a Design Basis Accident.
Engineering
Design Change
QCQCInspection
Inspection
Limiting Conditions of Operation (LCO) – Plant events that
may call a Technical Specification into use
Design Basis Events and Accidents – credible postulated
events during plant life for which the NPP and its safety
systems are designed to ensure plant continued safe operation
or safe shutdown.
Fitted to Plant
as Equipment
MR
MRIssue/Return
Issue/ReturnVerification
Verification
Action
Tracking
Work
Management
Employee &
Timekeeping
18
Elements for CM - Basics about Classic CM and Nuclear Design Basis Management
 CM is the Preservation, Verification
and Recording of NPP Plant Design
Basis
 CM is supported by NPP IMS, NKM,
PLM and MRO NPP Programs and
Processes, and CM should be
integrated as a part of the IMS
Program.
Audits QA Program & Plan NCR’s
Document Reviews Commitment Tracking
Process Review and Templates
QA
Integrated
Integrated
Management
Management
Systems
Systemsjoin
join
the
theCM
CMand
andQA
QA
functions
functionsinto
intoaa
complete,
complete,
reliable
reliableNPP
NPP
quality
qualitysystem
system
Programmatic
Integrated Management System
Practical
Equipment
Design
Documents/DBD
Design Changes
Changes
Documents/DBD
Work
Work Management
Management Materials
Materials && Parts
Parts
 The Configuration Management
CM
Infrastructure – Management
Processes, Procedures, Technology
Solutions for (1) Data Creation &
Capture, (2) Review and Content
Management, (3) Production MRO
The
TheThree-Tier
Three-TierModel
Modelfor
forManagement
Management
ofofCritical
CriticalCM
CMData
Data
 CM and IMS Programs for New Builds
Data Generation
A “Tier”-based deployment plan for
Enterprise NPP Solution for Design,
Construction and Operation Phases of plant
development
CADD, construction data, Intergraph PDS, simulation, CAE, engineering
data sheets, Action Items, CARs, project management, etc.
PROCESS CONTROL
or Operating NPP’s have most
characteristics in common, with
special considerations for EPC and
supplier relationships
Concept & Design Data
Concept & Design Data
Data is as
PLM
Design & Construction
Design & Construction
complete
as possible
Data Review/Approval
Document Manager (EDMS), Engineering Workflow
& Routing (eProcess EDR), Action Tracking.
PLM
Operation
Operation
Enterprise CM
Data is
validated as
much as possible
MEL, DCM, ECC, Materials, Work Management, etc.
19
Preserving the Design Basis from Design to Documents
Design Basis
Master
Equipment
List
Vendor and
Licensing
Documents
I N
P
U
Understanding the Design - CM will
facilitate to prevent losses of regulator
and public faith and achieve Operational
Excellence goals, and ultimately, avoid
expense and risk of shutdown and/or
performing a costly design basis
reconstitution.
Design Basis
Documents
T
S
Creation
Creation of
of aa Plant
Plant Design
Design Basis
Basis
Plant
Design
Basis
Design Requirements from Plant Vendors and
Constructor, as well as Equipment Requirements and
Determinants, such as Operating Factors, LCO’s,
Technical Specifications, etc. determine a Design Basis …
Design and
Work Order
Order
Execution
for
Installation
Equipment and Engineering
Design
Understanding the Equipment – The
Engineering Design Process will specify
and place the proper equipment for the
Design Basis needed – for Safety and
Operation
The Work Management Process Records and
Documents the Installation, Testing and
Commissioning of the Design Change
solution in the Physical Plant…
Startup Tests
and
Commissioning
To Design Basis Documents
Work Order Closeout
Design Basis
Update
To Design Basis Documents
Controlled Documents
Engineering Design Change
Design
Documents
Component
Procurement
Specifications
Assure Safety by Preventing
Mismatches in Plant Design Basis,
Documents and Equipment Content
Resulting in Shutdowns, Accidents,
Exposure

Prevent Losses of Regulator and Public
Faith

Establish and Maintain Responsible
Engineering Practices


Achieve Operational Excellence Goals

Step Increase in Efficiency, by
Reduction of Shutdowns, Maintenance
Rework, and Materials Spend

Smooth and Refine NPP MRO and
Nuclear Business Processes
Parts Substitutions
Minor Design Changes
Quality Records
Physical
Plant
Design Basis
Document
Creation/Revision

Design Basis
Reconstitution
The Engineering Design Change Process utilizes the
Design Basis as Input. It may also modify the Design
Basis, which must be documented in the Design Criteria.
Affected Design Documents are then created and/or
updated, and Procurement Requirements for parts are
determined …
Understanding the Documents Nuclear Power Plants, in particular, have
CM requirements that go beyond
commercial or efficiency considerations.
Nuclear Power deals with the requirement
for 100% safe operation and positive
design control, as represented in
Controlled Documents.
Avoid Expense and Risk of Shutdown
and/or Design Basis Reconstitution
20
Information Technology-based CM and IMS
CREATE
CREATE
REVIEW
REVIEW&&APPROVE
APPROVE
PUBLISH
PUBLISH
Archimed
Knowledge
Portal
EPC & Vendor
Source Data
Engineering/3D
Engineering/3D
Design
Design Review
Review
Construction
Construction
Materials
Materials Qualification
Qualification
Procurement
Procurement
Turnover
Turnover
Meta
Meta Data
Data and
and
XML
XML Data
Data
Dictionaries
Dictionaries
MRO
MRO
Archimed
Archimed GSR3
GSR3
Engineering
Engineering
Content
Content
Management
Management
PLM
eProcess
eProcess
Correspondence
Correspondence Mgr
Mgr
Parent Corporate
ERP/Accounting
PLM
eDMS
eDMS Document
Document
Manager
Manager
Siemens
Siemens PLM
PLM
TeamCenter
TeamCenter
Nuclear
Nuclear
PLM
SAP
SAP R3
R3 ERP
ERP
eDR
eDR Engineering
Engineering
Design
Design Review
Review
SmartPlant
SmartPlant 3D
3D
CADD
CADD Design
Design
Data
Data and
and
Business
Business Models
Models
SmartPlant
SmartPlant
Foundation
Foundation
Example CM, IMS and MRO/ERP design for Belene NPP
using Archimed GSR3, Intergraph and Siemens
TeamCenter Nuclear IT solutions
3D
3D Render
Render
Three-Tier CM and Design
Management technology systems for
enterprise Configuration
Management in Nuclear Power
plants is implemented at the Belene
NPP project.
21
Design Basis Retention & Configuration Management


Safety Analysis Report (SAR) and updates

Equipment and Component Procurement
Specifications

Technical Specifications and Operating
Parameters

Equipment and Operating Plant Programs, such
as Seismic and Environmental Qualification, Safe
Shutdown, Fire Safety, ASME ISI, ATWAS, Loss
of Offsite Power, etc.

Materials
Management
Catalog ID
Q-Level
Industry and NGO Standards (IAEA, WANO,
EUR, WENRA)

Component Manufacture Certificates and
Passports



Materials and Parts Qualification

These documents
are an integral part of the NPP
licensing and design process, and
form the basis for operating
license
compliance
NSSS Vendor Design Requirements (WCAP) and
Design Technical Specifications
5
Master Equipment
List
Equipment ID
1
Engineering
Change Control
NSSS, Vendor and Manufacturer
Correspondence
Work Order
Number
Modification
Number
Design Basis Drawings and Documents
Installation Work Orders and Field Design
Changes
Work Management
Document Control
3
4
Document Number
Sheet
Revision
2
22
Nuclear Knowledge Management



Capture of latent and potentially lost
knowledge among nuclear operators
Daily NPP Operations: Information,
Facts, Design Data and Operating
Experience acquired, reviewed,
corrected and verified as part of
normal NPP operation, then
recorded and documented to
maintain plant configuration
Latent Knowledge: Information,
Experience and Knowledge
accumulated over time by personnel,
which may or may not have been
formally recorded or documented.
CM and MRO Data
from Daily NPP
Operations and Work
NPP Processes,
Procedures and
Business Rules
Known NPP Experience
Repositories (OE, ISEG
Reports, System
Engineering, etc.)
Configuration Management
and MRO Systems
Knowledge
Coincidental to Daily
NPP Work
Nuclear Business Systems
Maintenance Resource
Optimization (MRO)
Information/Data “PUSH”
Information/Data “PUSH”
Configuration Management
(CM)
MRO/ERP Systems
(Passport/Asset Suite,
MAXIMO, TeamCenter)
Enterprise Resource
Management (ERP)
Plant
Lifecycle & IT
Communication Bus
NPP Nuclear Knowledge
Management Systems
NKM Repository and
Publication Tools
Undocumented Facts
Information/Data “PUSH”
Information/Data “PUSH”
Experience
NKM Program Media:
Interviews, STAR Audits,
Outage Debriefs, etc.
Vendor and Contractor
Technical, Design and
Process Information
EXCELL/Informatics
Lessons Learned
Knowledge Base
Search Engines
NKM Capture Portal
(INTUIT, EXCELL,
Informatics)
Operations Data
Work Management,
Alignment, Process
Control
Commissioning
Data
Materials
Catalog
Procurement
Scheduling
Book of Knowledge
Data Repository
CADD / PDS
Content Management &
Design Review Control
Construction &
Labor Data
Correspondence
Process Control
Engineering Design Data
Design Basis Library
Master
Equipment List
Document
Document
Management
Management
Engineering Analysis & Codes
Circuit & Raceway
Piping Analysis
Valve Lists
Legacy &
Baseline Data
Prevent
“Loss of Memory” and Loss
of Valuable NPP Operating
Experience
23
NPP Integrated Management Systems (IMS)






Template-based, unified quality
management and development of
consistent processes and procedures.
Follow IAEA GS-R-3 Management
System Principles
NPP software and systems are
developed to support GS-R-3
requirements and best practices for
processes.
Consistent implementation of processes
and procedures ensures that NPP
Operation and Design Basis.
NPP MRO, CM and Business Software
and Technology choices are very
critical for IMS to be properly deployed
Best utilized with Plant Lifecycle
Management (PLM)-based information
system technology solutions.
IMS
Integrated Management Systems and
GS-R-3 concepts are utilized by Belene
for NPP Management Systems
development and implementation.
Asset Management
Risk Management
Business Planning
Performance
Improvement
Change Management
Configuration
Management
Communications
Requirements and
Grading
Environmental
Management
Industrial Safety
Information
Management
Security
Regulatory
Compliance
Human Resources
Training and
Qualification
Design Basis
Technical & Reactor
Governance
Document Control
Records Management
Emergency
Preparedness
Project Management
Knowledge Capture
and Portals
Skills and Knowledge
Mapping
Enterprise Resource
Planning
Work Management
Engineering
Design
Work Management
Change and MEL
Operations, Tagout
Work Management
and Configuration
Warehouse,
Work Management
Issue/Return and QC
Receipt
Preventive
Work Management
& Recurring
Maintenance
Work Management
Qualification
Programs
Nuclear Fuel
Outage Management
Safety and MSDS
Purchasing
Internal/Self
Assessment
External Assessment
Audits
Operational
Experience
Asset Condition &
Performance (CAP)
Financial Controls
M anagem ent
S ys t e m s &
Pr ogr am s
Res our ce and
K n o w le d g e
M anagem ent
P r o d u c t io n a n d
O p e r a t io n s
Catalog
and Materials
Work Management
Management
NPP Plant Process Matrix
NPP Plant Process Matrix
A s s es s m ent s
and KPI
Control
Health
Physics/Radiation
Protection
Work
Procurement
Management
Engineering
24
New NPP Construction and Design Basis Management
REQUIREMENTS AND
REQUIREMENTS
AND
SPECIFICATIONS
SPECIFICATIONS
 Development and preservation of the
Design Basis begins on the first day of
the design process.
 Information Technology and a broad,
DESIGN
DESIGN
PLM-based Network Infrastructure are
needed to communicate design and
equipment manufacture requirements
between construction parties (EPC,
Owner’s Engineer, Owner-Operator
and Suppliers).
 Design Decisions, Review and
Comments, Component NonConformances and Field Design
Changes must be communicated
immediately to the Project via a
Configuration Management (CM) and
MRO infrastructure.
 Use of 3D Modeling and Design
CONSTRUCTION
CONSTRUCTION
Platforms, Integrated with CM and
Design Information Technology to
create a seamless design environment
over a PLM backbone.
25
Applicability to USA
Configuration Management Programs
•
Both documents authored by nuclear professionals involved in current
USA programs and familiar with leading commercial nuclear software
solutions
•
Enhance understanding of current trends in nuclear new build licensing
and CM Requirements.
•
Documents are written in context of most recent developments in overall
nuclear power betterment infrastructure, including Integrated
Management Systems (IMS), Knowledge Management (KM) as well as CM.
•
Recognition of new technology solutions which change the landscape of
implementing CM programs for new builds
•
Closer integration of Architect/Engineers, EPC’s and suppliers in the new
build CM requirements.
•
Improved understanding of contractual requirements for new build NPP’s
in the areas of IT and CM.
26
Applicability to USA
Configuration Management Programs
• EPRI Advanced Nuclear Technology Program
and Standard CM Models for NNPP’s
• Process-Oriented Knowledge Management
Programs and CoP’s
• New Requirements for Enterprise NPP
Technology Solutions from Owner/Operators and
new-build EPC’s
27
Questions?
Thank you!
28