Oracle Applications in Nuclear Power Generation Industry Case: Nuclear Power Plant Krsko, Slovenia Presenters: Mr. Hrvoje PERHARIC, NEK, Member of Management Board Mr. Zeljko RELJIC, NEK, EBS Implementation Project Manager Mr. Stane MOSKON, OSIR, Partner Oracle Open World 2010 Bejing KRSKO Nuclear Power Plant: implementation of ORACLE EBS & eAM Hrvoje Perharic - Brief overview • Since 1982 in the Krško NPP: – – – – operation department: shift supervisor (SRO) plant technical director (plant manager) today: member of management board sponsor of major IT project including eBS KRSKO NPP - General Plant Data • Westinghouse 2 loop Pressurized water reactor (PWR) of 2.000 MW thermal power. The power plant's net electrical power is 696 MW. It is connected to the 400kV grid supplying power to consumer centers in Slovenia and Croatia. • Investment of two governments (Slovenia & Croatia), utilities • Gilbert architect engineer • Plant history: • construction start in 1975 • September 1981 first criticality • Januar 1983 commercial operation • Number of employees: <600 • NEK generates over five billion (109) kWh of electrical energy per year, which represents approximately 40% of the total electricity produced in Slovenia, and 17% in CROATIA. • fuel cycle: eighteen months. This is the operational orientation of the power plant 3 Performance unit capability factor from year 2008-2010 NEK’s Vision In terms of nuclear safety, operational stability and business performance, our aim is to be classified among the best operating nuclear power plants in the world. 4 Business processes & challenges the focus on maintenance ● Nuclear Regulatory Commission (NRC) ● NRC Statement on maintenance in regard to the maintenance rule (Regulatory Guide 1.160) “Proper maintenance is essential to plant safety. As discussed in the regulatory analysis, there is a clear link between effective maintenance and safety as it relates to such factors as the number of transients and challenges to safety systems and the associated need for operability, availability, and reliability of safety equipment. In addition, good maintenance is also important in providing assurance that failures of other than safetyrelated structures, systems, and components (SSCs) that could initiate or adversely affect a transient or accident are minimized. Minimizing challenges to safety systems is consistent with the NRC's defense-in-depth philosophy. Maintenance is also important to ensure that design assumptions and margins in the original design basis are maintained and are not unacceptably degraded. Therefore, nuclear power plant maintenance is clearly important in protecting public health and safety.” 5 NPP industry • TMI and Chernobyl (1979 and 1986) – INPO (Institute of Nuclear Power Operators) – WANO (World Association of Nuclear Operators) • Industry collaboration is required and become regular – OE exchange – – – – – – • WANO SOER&SEN, JIT, .. Evaluations Benchmarking Technical support missions Best practice guidelines Nuclear network Obsolete parts • Example of collaboration within the industry during eBS project at NEK – – – – Challenges with re-engineering of inventory master item definition Questions posted to mailing list of systems engineers As a result common agreement within NEK was reached and topic closed. WANO Technical Support Mission • IT and e-processes are becoming a must in supporting business processes in NPP industry. Current business process challenges or system limitations • Number of NEK internal requirements for maintenance management SW • Existing applications upgrades & maintenance-Lack of professional IT-resources (even for maintaining existing scope of current legacy system- Aging workforce & availability of key skills) • Improvment of NEK processes (management & e-bussines). Number of additional requirements for new IT solution. • New business related legislations (EU) • International Accounting Standards 7 NEK Project Goals • New process considers NEK good practices and industry good practices (WANO, IAEA, INPO, EPRI) • Long term IT solution to support continuous plant effort to improve plant safety and reliability as well as cost effectiveness of plant operation by having proper business processes management tool • To assure NEK IT personnel and subcontractor knowledge necessary for long term local support. • To bring NPP specifics requirements based on NEK and industry good practices to become generally accepted standard • New acquisition important for NEK: ORACLE & Primavera 8 NEK main concern • How ORACLE will prove its commitment to follow-up nuclear industry requirements in the future (like WANO, INPO, IAEA, EPRI, ..). 9 New Nuclear Risks such are: • • • • • • regulatory engagement rulemaking regulatory permitting safety margins general public support financing capital costs Construction management and productivity can be managed by having early in place such an IT tool KRSKO Nuclear Power Plant: implementation of ORACLE EBS & eAM Zeljko Reljic - Brief overview • Since 2009 - ORACLE eAM customer advisory board - ORACLE member of NPG SIG - ORACLE member of Fusion Asset Strategy Forum • Since 2007 - Project manager for EBS & eAM implementation at NEK • Since 1982 - CIO, NEK • Since 1978 - IT Superintendent, Westinghouse – during construction of NEK 11 NEK-Oracle relationship • NEK has used Oracle technology since 1986 • Primavera since 1999 • Implementation of eBS/EAM since 2009 Relationship NEK & Oracle • Feb. 2009-ORACLE PROPOSAL- “We hope NEK will join Oracle in constructing a next generation vision of technology application in nuclear utilities.” • May 2009-MEMORANDUM OF UNDERSTANDING – Weekly Call with EAM Product Strategy group Oracle – initiation Nuclear Power Generation Special Interest Group (NPG SIG) – NEK continuing participation in Health and Safety Feature Design (permits, isolations, locks and tags) – NEK participation in eAM Customer Advisory Board • Enhancement Priorities (a list of requirements )-voting • NEK Goal:To bring NPP specific requirements in the future as standard solution 15 NEK perspective on partnership with ORACLE • To implement IT solution around which we can to gather other NPPs • It is NEK interest to supporting Oracle in gathering other users from industry. By this the NPG SIG would become more influent on development path of standard EBS(eAM) solution. We are sure, that many practices from nuclear industry would be helpful to other industries. • It is NPG SIG interest to follow-up nuclear industry requirements in the future (like WANO, INPO, IAEA, EPRI, ..). • Oracle Nuclear Interest Group can influent software development in direction to improve nuclear safety, industrial safety, and reliability of the utilities that use Oracle products. • Oracle invited NEK to become member of Fusion Asset Strategy Forum 16 NEK inputs to the partnership • Know-how of the nuclear standard processes in the industry. • NEK active membership in industry organization: – WANO Paris center – INPO Atlanta center as IPAC member, – WOG Westinghouse owner group, – EPRI Electric Power Research Institute, – … • NEK may assure WANO technical support mission in test phase of project to evaluate appropriateness of the product vs. standards of processes in NPPs. • NEK is actively involved in benchmarking processes to other EU and USA nuclear power plants. • NEK is active user of Oracle technologies and Primavera for planning the projects. NEK has connected Work orders system (Oracle) and Primavera projects since 1999. 17 Engagement of NEK on ORACLE HQ (2010) • 4th Annual Customer Maintenance Summit - March 9th and 10th • 2nd Nuclear Power Generation Special Interest Group (NPG SIG) event - March 9th and 10th • Customer Advisory Board (EAM) – Aim to get priority in development for nuclear functional enhancements in EAM Weekly calls with EAM product strategy group • Discussions about: – Intended functionalities – Proposed design reviews – Technical problems and challenges • Discussions are very fruitful and many issues are being solved. EAM Nuclear Specifics • • • • • • • • Asset Modeling Supporting Specific Equipment Attributes Bills of Materials Safety and Criticality Classification Computer Kiosk Application Main Control Room Shift Supervisor Overview Scheduling Synchronization with Primavera P6 r7 Safety Permits NEK Asset Hierarchy NEK Asset Database Scope • A number of separate asset databases will be moved to single EAM asset database – Master Equipment List (functional locations) – Measuring and Testing Equipment – In Storage Maintenance Equipment and Parts – Buildings, grounds and rooms – Virtual Assets (asset routes) • Huge terminology challenge! Supporting Specific Equipment Attributes • Functional location design attributes, e.g. – Reactor Building Integrity, Building, Elevation, Room – Tech. Spec., Safety Class and Safety Function – Criticality, System, Train, Seismic, Explosion Zone,… • Relationship between attributes established – Forced logical dependencies – Preventing data entry errors – E.g. equipment zone depends on room zone • Advanced descriptive flexfield capabilites used Bills of Materials Solution • Compliance with Equivalency replacement evaluation process per EPRI NP-6406 – Engineering Change Order Process – Multilevel Bills Support – Part safety Classification Enhancements of BOM page Nuclear Safety and Criticality Classification • Established Process and Tool – Component nuclear safety classification – Component criticality classification – Spare parts safety classification Computer Kiosk Application • Up-to-date reporting of work start, pause, handover and finish by work coordinators and first line supervisors directly on the field • Instantly displayed to main control room shift supervisor. • Secure RFID supported identification • Touch screen compatible interface Main Control Room Shift Supervisor Overview • Full online overview over current and planned maintenance work in the plant to main control room. • Online integration to EAM system and kiosk application. Scheduling Synchronization with Primavera P6 rel. 7 • Work orders are tied to system windows • Only system windows and base activities are being scheduled in Primavera P6 • A process can be run to automatically synchronize work orders to system windows Safety Permits • One of recent EAM functionalities (available in 12.1.3) • A flexible tool to support various types of safety permits • At NEK used for – Clearances and Tagging (Integration with eSoms), Lifting & Rigging, Health Physics, Foreign Material Exclusions, Fire Protection, … EAM Nuc Specifics Summary • Most of requirements were covered with standard functionalities – Oracle EBS DFF & personalization capabilities were crucial – Small PL/SQL extensions • Specifics were covered with custom bolt-on applications • Business processes workflows are combined with Approval Management Engine (AME) Oracle Applications in Scope • Financials – – – – – – General Ledger Payables Receivables Cash Management Assets BI Applications - Oracle Financials Analytics Fusion Edition • Procurement – – – – – – Purchasing Sourcing Services Procurement Procurement Contracts iProcurement BI Applications - Oracle Procurement & Spend Analytics Fusion Edition • Inventory Management – Inventory • Projects – – – – Project Costing Project Portfolio Analysis Project Management BI Applications Projects Analytics • Enterprise Asset Management (eAM) – – – – – Asset Management Maintenance Budgeting Work Order Requests Work Order/Work Management EAM Cost Management • EAM supporting modules – – – – Bills of Material Cost Management Quality Work in Process • HRMS • Approval Management Engine (AME) 32 PrePostOutage Outage Outage Integrated Workplan with key milestones 01.12. 2010 01.01. 2010 01.02. 2010 01.03. 2010 01.04. 2010 01.05. 2010 01.06. 2010 01.07. 2010 01.08. 2010 01.09. 2010 01.10. 2010 01.11. 2010 01.12. 01.01. 01.02. 2010 2011 2011 01.03. 01.04. 2011 2011 Post prod. phase Build phase 2 Build phase 1 P1 30.11. – 4.12.2009 Pilot1 workshop Transition phase 07.01 - 15.07 Phase 1 16.07 - 19.11 Phase 2 16.07.2010 – 01.03.2011 25.10.-08.11. 18.10– 22.10.2010 P3 Close open issues-Pilot 3 Pilot 3 Testing 11.01.-05.03. Closure of Build phase Close open issues-Pilot 1 12.11 UAT 06.12 – 17.12 WANO technical support mission UAT Testing 24.05.-28.05. Security 17.01.2011 Profiles Go live readiness 01.06.2010 19.07. – 11.10.2010 decision P2-Design freeze Close open issues-Pilot 2 P2 03.01.2011 Prod setup PROD 05.03.2011 Go live 19.01. –28.02 22.02. –11.06.2010 Trial 1 data migration 16.08. –03.12 Trial 2 data migration Prod migration End-user training Procedure revisions eSOMS project Competence center delivery under EBS project monitoring and jurisdiction 33 WANO TEV For the purpose of eBS implementation evaluation Krsko NPP asked for WANO technical exchange visit (TEV). TEV was performed from May 24-28, 2010 and it focused on: – work management, – especially software implementation, and – equipment reliability. WANO TEV findings • Areas with recommendations are as follows: Identification of Critical Components and Critical Spares Materials Management Work Planning and Scheduling Improvement Preventive Maintenance Operability Determinations Quality Inspections Change Management and Project Implementation Software Modifications • All the recommendations will be fulfilled within eBS implementation What can other nuclear energy companies learn from our experience in implementing Oracle eAM and EBS? • NEK decision process and key reasons for decision for Oracle Applications • NEK experience how to meet compliance with functional and regulatory requirements? • How to define business requirements and how to meet them: – shorten outage (overhaul) – achieve more safety and reliable maintenance process – achieve higher efficiency of maintenance processes – perform solution validation – achieve paperless maintenance process • Implementation project knowledge and experience 36 Stane Moskon - Brief overview • Osir d.o.o., Partner and Procurator • more than 35 years in IT • holds international certificates: – CISA (Certified Information System Auditor) – CISM (Certified Information Security Manager) 37 NPGSIG Community • The idea to establish NPGSIG was raised in year 2009 during the meeting between Oracle and NEK. • Today has NPGSIG community near 1000 members. • Communication channels: – Personal contact (Oracle, NEK, Osir, … ) – NPGSIG web page – registration (near 100), – Social Networks: • NPGSIG on LinkedIn (more than 770 members), • LinkedIn Contacts (additional more than 150) • Facebook • Twitter NPGSIG – general information 39 Nuclear Power Generation Special Interest Group (NPGSIG): • was established on October 16th 2009 at Oracle Open World in San Francisco • by Oracle, NEK , OSIR … NPGSIG key goals: The purpose and goals of NPGSIG are to join existing and future Oracle Applications users in nuclear power generation organizations, to exchange experiences with implementation and using of Oracle Applications, to establish best practices models and to set up the competence centre for using Oracle Applications in nuclear power plants. Some statistics data: • Near 1000 members of NPGSIG community (976) • More than 220 members from 47 nuclear power plants from all around the world • More than 200 members from nuclear power generation industry (IAEA, INPO, WANO, EPRI, Westinghouse, Areva, GE energy, AMEC, …) • More than 2200 visitors of www.nogsig.org from 76 countries all around the world • Communication of possible cooperation with: Taohuajiang Power and Guangdong Corporation(China), ENEC (UAE), Rosatom (Russia) NPGSIG web page 40 NPGSIG Group Members Members (234) from NPP (49): Entergy, USA First Energy, USA Constellation, USA Progress Energy, USA Exelon Nuclear, USA FPL, USA TVA, USA American ElectricPower, USA Ontario Power Generation, Canada Bruce Power, Canada EDF, France GDF-SUEZ, France Comex Nuclear, France Magnox North, GB Quest Nuclear, GB Rosatom, Russia NNEGC Energoatom, Ukraina SN Nuclearelectrica, Romania Alstom Power, Romania ESKOM, South Africa PBMR, South Africa Dhruva Nuclear Reactor, India NPP Krsko, Slovenia RWE, Germany GEN energija, Slovenia 41 Members from other NPP related companies: Westinghouse, USA Shaw Group, USA GE Energy, USA CSC, USA Wiz Nucleus, Usa PTC, USA Atomic Energy of Canada AMEC NCL, Canada AMEC, UK Areva NP, France Hitach Nuclear, Japan Mitsubishi Heavy Industry, Japan Electrebel, Belgium Alstom Power, Switzerland Alstom Power, Romunia CANDU, Canada IAEA, Austria INPO, USA EPRI, USA, WANO, USA APTUS, France Bhabha Atomic Research Center, India NPGSIG web statistic of visists and visitors 42 NPGSIG web page visitors by countries 43 NPGSIG LinkedIn Group 44 NPG Competence Centre NPGSIG has in program: In year 2010 set up of NPG Competence Centre in NPP Krsko. NPG Competence Centre purpose and goals: • Organize reference visit for potential users from nuclear power generation industry. • Organize training for nuclear power geneartion specific functionalities in eAM and other modules (Purchasing, Inventory, …). • Organize workshops where participants can find answers on specific questions. • Execute functionality and stress testing for potential users. • Execute Pilot according to specification and requirements. 45 Organization of NPG Competence Centre is supported by NEK, Osir and Oracle. NPG Demo System Set-up The main goal of NPG Demo System is to speed up future EBS implementation in nuclear power plants using EBS preconfigured instance. • NPG Demo System will be based on solution we are currently implementing in Nuclear Power Plant (NEK) in Slovenia. • In NPG Demo System will be included: – Nuclear Specific functionalities (Permits, Shift Supervisor Screen, Nekomat, …), – Nucleal specific workflows and approvals, – Nuclear specific cases for NPP generalized processes, – … NPG Initial Set-up The main goal of Initial Set-up is to start building asset hierarchy from the beginning of NPP construction process. • NEK experience – it took 53 men years to build MECL (Master Equipment Component List). • Suppliers have to prepare data for every component according to the predefined specifications in agreement between them and NPP in construction. © 2010 Oracle Corporation – Proprietary and Confidential NPGSIG Community is ready and waiting to exchange experience, knowledge and information. 49