PAGE 1 New Plant - CM Configuration Management For The Next Generation Of Nuclear Facilities Joseph Burack Consulting Engineer Configuration Management

PAGE 1 New Plant - CM

Configuration Configuration ManagementManagement

ForForThe Next GenerationThe Next Generation

OfOfNuclear FacilitiesNuclear Facilities

Joseph BurackConsulting Engineer

Configuration ManagementSouth Texas Project

Friday, April 21, 2023



Using CM principles, lessons learned from the current generation, and the latest Information Management tools, develop the foundation for a state-of-the-art CM system that will meet both requirements and end-user needs for the life cycle of the facility


How do we get it?Issue CM Policy

1. Establish Executive Management Support

2. Apply to Owner & EPC

3. Issue in COLA/Design Phase


Develop CM Program

1. Owner Developed w/end user in mind

2. 2 Phase Approach• Pre-Operational Phase• Operational Phase

3. Apply Pre-Operational Phase to Owner & EPC

4. Implement early in Design Phase

5. Provide definition and implementing functions

How do we get it?


1

Conceptual

Design -COLA

2

DefineMajor

Components

3

DevelopFinal

Design

4

Construct/Refine

5

Test/Turnover

6

OperateMaintainRepair

CM Program Functions

Pre-Operational CM Program


1. Definition/Objectives

2. Ownership/Organization/Training

3. Identification

4. Change Control

5. CIMS

6. Verification and Audits

CM Program Functions


CM is a set of processes, practices and tools for

establishing and maintaining the design integrity of a facility

throughout its life cycle.

CMP Function - Definition


1. Establish and Maintain Conformance between CM elements

CMP Function - Objectives


=

= =REQUIREMENTS

PHYSICAL PLANT/SIMULATOR

INFORMATION

CMCMPEOPLE P

RO

CES

SES

PR

OG

RA

MS

PROCEDURES

FSAR Tec h

Spe cs

Design

Basis

CM- Objective


2. Provide valid and timely configuration information to users in an efficient

manner.

CMP Function - Objectives


Training

Procedures

Simulator Updates

Plant Drawings

Maintenance

Procedures

Drawings

Vendor Manuals

Material Substitution

Parts

Procurement

Specifications

Material Lists

Spare Parts

Engineering

Design Basis Documents

Calculations

Design Drawings

Permanent Modifications

Temporary Modifications

Specification

PMs

Licensing

FSAR

Technical Specifications

Configuration

Management

InformationSystem

Operations

Emergency ProceduresSpecial Test Procedures

Equipment Tagging

Normal Procedures

Plant Drawings

Surveillance

Setpoints

CM- Objective


1. Establish STP as Owner

2. Define CM Organization – STP/EPC

3. Perform CM Training – STP/EPC

CMP Function - Ownership/Organization/Training


ISSUE

EPC Organization

EPC consists of many entities; all who are used to doing business “their way”.



ISSUE

EPC CM Organization

EPC does not have anyone “in charge” of CM. Standard response is “we all do it”. CM to EPC is simply “document control”.



Result


1. Identify the Scope of facility SSCS to which CM is applied.

2. Identify Baselines.

3. Identify (number) Documents and Equipment.

CMP Function - Identification


BASELINES

Baselines – Configuration Information that identifies and establishes the attributes of a facility at a point in time (specific plant design freeze) and serves as basis for defining change.

• Baseline License Requirements – Established when COLA submitted• Baseline Documentation – Rev 0 STP documents• Baseline Configuration Items (CIs) – EPC?



ISSUE

EPC Contractor does not understand Baseline.



Develop a Plant Numbering System

• Keep it Simple and Intuitive

• Involve Operational Phase End-Users



1.End Users want to know

• Unit/System/Component Type/Unique No

– U7-RHR-PMP-001A

• Unit/Doc Type/Subtype/Unique No

– U7-P&ID-RHR-001


U3-RHR-PMP-001A

Unit/System/Component Type/Unique No

Unit/Doc Type/Subtype/Unique No

U3-P&ID- RHR-001


ISSUE

EPC wants to use their numbering system.

STP wants to use their numbering system.




Solution

Use both Numbering Systems.

Treat EPC as a Supplier/Vendor


RMS/DC

STP Doc.#

Supplier Doc.# 3E11-2101-0001-01

U3-P&ID-RHR-0001-01

EDB

STP CID#

Supplier ID# E11-C001A

U3-RHR-PMP-001A


U3- RHR- PMP-001A(C001A)

RESIDUAL HEAT REMOVAL PUMP 1AComponent Tag


1.Develop single, standard Change Control process for use by STP/EPC

2.Invoke Change Control on ALL Baseline (Rev 0) Configuration Information

3.Do not allow One-Time or Unincorporated changes

CMP Function – Change Control


ISSUE

Potential - Getting various members of EPC to use a single Change Control Process may be difficult.

Selecting which changes will be reviewed by Owner requires significant consideration.

CMP Function – Change Control


1. Develop a Configuration Information Management System (CIMS)

• Relational RM/DC & Equip Databases

• CIMS must be available to Designer, Constructor and Owner/Operator

• Implement CIMS at onset of Design Phase

CMP Function – CIMS


1. Develop a Configuration Information Management System (CIMS) - cont’

• Populate CIMS as design is developed

• Cross-Reference/Link Documentation to SSCS and vice versa as design is developed.

• Must be “expandable and transferrable”.



Application Architecture

Figure 1. CM Links Between Information Source Contents



Functional Architecture

Document

Control Information

System

Pla

ntB

asel

ine

Val

idat

ion

Procu

rem

ent

LicensingQualityAssurance

Plant

Performance

Optimization

Training

Con

figur

atio

nB

asel

ine

Engine

ering

Chang

e

Contro

l

MaintenancePlant Procedures

DataDrawings

Text

Figure 2. Plant Configuration Management Functional Wheel



EDB RM/DC

U3-RHR-PMP-001B

U3-RHR-MOV-010B

U3-RHR-STRN-001B

U3-RHR-PX-002B

U3-RHR-HX-001B

U3-RHR-PI-013B

U3-RHR-PT-004B-1

U3-RHR-PT-004B-2

U3-RHR-PT-004B-3

U3-RHR-CVLV-002B

…….

STP Doc #

Supp Doc# 3E11-2101-0001-01

U7-D-P&ID-RHR-001-02



EDB RM/DC

U3-RHR-PMP-001B

•Meta Data

•Attributes/Limits/Setpoints

•Margins

•Parts

•Risk

•PMs

•Work History

P&ID-RHR-001-02

CALC-RHR-001

SDD-RHR-001

FSAR-CHP-2.4, 5.4.7, 6.2

SPEC-RHR-0001

P-0P02-RHR-0001

VTD-G062-0001

T.S.-3.4.7, 3.4.8, 3.6.2.3, 3.6.2.4, 3.9.7, 3.9.8



CMP Function – CIMSISSUE

Potential - Getting members of EPC to agree on a single platform (Information System) may be difficult.

Each member wants to use their own System.


1. Verification and Audit Purposes

• Provide confidence that facility definition formation is under configuration control.

• Ensure that the facility design agrees with requirements.

• Validate that the design has been accurately documented.

CMP Function – Verification & Audit


1.Verification and Audit Purposes – cont’d

• Validate the integrity of the facility configuration information

• Validate that change control process is adequate

• Validate that CM objectives have been satisfied.

CMP Function – Verification & Audit


But, at the end of the day: