Intergraph and PWC Interoperability With SAP For NPPs

NPP Configuration Management across the Plant Life Cycle
using
Intergraph's Configuration Management Information System
and PwC's Nuclear Template for SAP
SAP for Nuclear 2012

February 14, 2012
Keith Denton, Vice-President Global Power Industry, Intergraph

Brian Williams, Director, Utilities, PwC
Proprietary & Confidential Information.

© 2012. Intergraph Corporation. All Rights Reserved.
No Reuse without written Permission.
Agenda
 Introduction
– Your Presenters
– Configuration Management and our journey to Interoperability
 Configuration Management across the Plant Life Cycle

– The Old Way: The Document/ Metadata Paradigm
 Plants constructed in the 70’s and 80’s
 Operating Plants
– The Way Forward: Intergraph and SAP Interoperability

 New Build (Greenfield)
 Operating Plants
2 © 2012. Intergraph Corporation. All Rights Reserved. Proprietary & Confidential Information.
Agenda
 Benefits from Interoperability for NPP Configuration
Management
– New Build (Greenfield)
– Operating Plants
 Interoperability Demo
– From within Intergraph SPF
– Using SAP NetWeaver Portal
 Conclusions
– What comes next
– Our Interoperability Team
– Q&A
Introduction
Your presenters
Keith Denton
Vice President, Global Power Industry
Email: keith.denton@intergraph.com
Mobile: +1 256 508 4413
Brian Williams
Director, Utilities, PricewaterhouseCoopers LLP
Email: brian.williams@us.pwc.com
Mobile: +1 919 794 1690
PwC Proprietary & Confidential Information.

4
© 2012. Intergraph Corporation. All Rights Reserved. No Reuse without written Permission.
The PwC Nuclear Template for SAP
– Pre-configured SAP content for NPP reference business processes

– Solution Manager repository with templates, process flows etc
– Training and change materials
– Proven project delivery practices
– Embodies the cumulative experience of Subject Matter Experts
– Emphasis on Operating Plants – now moving earlier into the life cycle
Three key drivers…

1. Risk management and compliance with safety,
environmental and quality requirements
2. Increased power output at required reliability
from existing plant
3. Reduced inputs (cost, resources) to EAM
process over asset life-cycle (c/kwh)

5
PwC Nuclear Template for SAP - Europe
ENEL Slovenske Elektrarne nuclear plants

– Accelerated blueprint and solution configuration
– Use of template to produce localized design and 80% baseline
– Solution configuration in ~ 4 months on-site
– Full specification of development objects
Kernkraftwerk Leibstadt (KKL) in Switzerland

– Met at this conference in 2011
– Completing “Coverage Analysis” to assess SAP fit for KKL
– Used the template to show how SAP can meet their needs
– Proved the adaptability and flexibility of the template

6
PwC Nuclear Experience - USA
Canada
•NB Power PLGS
•Bruce Power
NPPD
Nebraska Public
Power (Cooper)
PG&E PSEG Nuclear

Diablo (Salem and
Canyon Hope Creek)
SCE
SONGS
STPNOC
(South Texas Project)

PwC Nuclear Template for SAP in China

8
The Standard Nuclear Performance Model
Electricity
Production CAP
INPO 928
Operate Plant • Operate/Monitor S.S.C.

(INPO) • Monitor/Control Effluents
CORE PROCESSES • Monitor/Control Chemistry INPO 913
Configuration Work Management Equipment
Management (INPO) Reliability
SAP ECM (INPO) (INPO)
• Planning • Long Term Maint Plan

• Config Control
• Scheduling • ST’s
• Design Changes
• Preventive Maint • Perf & Reliability of S.S.C.
• Design Basis Changes
• Corrective Maint • Predictive Maint
• Fuel Management
• Decommissioning Plan
• Maint Non Plt Equip Procurement
• Plt Improve Maint
• Monitor Radiation Exposure Engineering
• Monitor Contamination
• Minor Maint
• Warehousing
SAP WCM Materials & • Inventory Mgmt
Services • Procure Mats & Svcs
(INPO) • Contractor Services
• Disposal & Surplusing SAP LSO
• Repairs, Returns & Svcs
SAP EH&S SAP PI
SAP EHS
Nuclear Fuel Support Services Loss Prevention Training
(NEI) (INPO/NEI) (NEI) (INPO)
• Provide & Transport Fuel • Information Services • Security Measures • Training Program
• Handle, Store, Dispose Fuel • Business Services • Perf Monitoring • Conduct Training
• Records & Docs Mgmt • Safety Measures • Attend Training
• Personnel Services • Licenses & Permits
Slide 9 • Maint Grounds & 766 • Emergency Planning
ENABLING PROCESSES • Support Comm & Govt • Fire Protection Proprietary & Confidential Information.
• Support Indust & Assoc No Reuse without written Permission.
Configuration Management
Reliability Operations Engineering Construction SCM Maintenance

Change Engineering Updates Anyone can
Document Design with As Built Data Initiate Change
Management Close Process
SCM Maintenance Operations Reliability Engineering

Operations Field Change Request
Synchronize As Built Identify > Describe >
with As Designed Data Recommend > Justify
Management
of Change
Asbuilt Field
Change Change Change Request
Execution Execution Process Request Process
Package 1,2,N
Construction Change
Contractor Design Process
Procure > Schedule > Install > MRB
Commission > Startup Material Review Board
Welders
Qualification
Weld
Procedures
Weld
Rods
Verify > Review > Approve
Used Used MRB Reveiw
Welding Package
TA Review EA?
Y
EA Review
Engineering
Welder
Isolation Pump OEM
Connecting
Name
P&ID Piping
N
Change Request
Valves Installation
Manual
Pipe Drawings
Spools
Isos
Engineering Tech Review TA?
Y
Pipe N
Materials
Pump
Pump
Number
Welded
Supporting Design Information
Engineering or EP&C From
Verify Step O&M Review
2 pt.
OK?
Y
To Approve
Step
Inspection Fasteners 3D
Design
Design > Review > Approve N
HSE Review
Drawings Pipe Design

Mechanical Gaskets Specs Tag
Completion Package
Design Change Reviewn
To Y N
Discipline Construction Notification Verify Step Clarify

? Cancel
Work Packages Questions Notify Initiator
Workflow
PwC Proprietary & Confidential Information.
10
Our journey so far…
 Intergraph
We realized that a tremendous wealth of plant design basis
information and procurement/ construction information were not
making it across to operations, and worse, the plant operators did not
know how to even specify the formats to be handed over or that data
other than drawings and documents was to be handed over at all.
 PwC
We realized that operating NPPs were not taking advantage of
advances in information technology. Specifically, NPPs are lagging
other industries in plant visualization, simplifying user interfaces,
knowledge management and use of mobile devices, to name a few.
In short, NPP’s are stuck in a 30+ year old paradigm

of documents/ metadata.
© 2012. Intergraph Corporation. All Rights Reserved. Proprietary & Confidential Information.
The Problem: Hierarchical Limits vs Molecular Reality
Old Way Way Forward
Data Sheet OEM DWG

FMEA
DATA Manual
SHEET OEM DWG
MFGR
Manual
DESIGN Number
PRESSURE
PUMP
MODEL eBOM
LOCATION
P/O
P&ID DWG Purchase
P&ID SERNO
Order
Most hierarchical Document Management Real information is massively inter-related

and PLM systems model their information and inter-dependent, and starting points
as represented by the familiar Cabinet → and navigation paths are unpredictable
Folder → File or Assembly → which does not lend itself to such neat, flat
Subassembly → Part paradigm. hierarchies
The Old Way: The Document/ Metadata Paradigm
Configuration Management - throughout the NPP lifecycle Engineering and

Maintenance must maintain a perfectly synchronized status:
 “What is required to be there, What we say is there, What is in fact there”
 Based on interviews and survey responses, $15.8 billion in annual
interoperability costs were quantified for the capital facilities industry in 2002.
 Of these costs, two-thirds are borne by owners and operators, which incur
these costs predominantly during ongoing facility operation and maintenance
(O&M).
 In addition to the costs quantified, respondents indicated that there are
additional significant inefficiency and lost opportunity costs associated with
interoperability problems that were beyond the scope of our analysis.
(National Institute of Standards Technology GCR 04-867)
“THE NEW WAY”
Intergraph’s Experience in Developing
A New Approach For Plant Data Interoperability
Process, Power & Marine Division
 Intergraph’s software is used by nearly all of the Fortune Global

500 chemical, petroleum, and pharmaceutical companies around
the world – as well as most EPC companies.
– We are the No. 1 provider of design and data management
software for the plant design industry worldwide, offering solutions for
engineering companies and plant owners.
– We have high customer satisfaction, offer best-of-class solutions, and
are No. 1 or No. 2 in the markets we serve.
– We are technology pioneers in 2D and 3D design.
– We have the premier integrated, enterprise-wide portfolio.
15
PP&M Worldwide Representation
Huntsville, AL
1,500 people worldwide

Corporate Headquarters Presence and local support
in 40-plus countries
Regional/Local Office
40-Plus Years of Success
Acquires SmartPlant® Releases

Launches PDS®, Instrumentation, now SmartPlant
now the world’s the industry’s No. 1 Launches Smart 3D Construction;
Becomes leading plant instrumentation technology (SmartPlant 3D acquires
Intergraph design solution design solution and SmartMarine® 3D) SIGRAPH.CAE
1980 1984 1999 2003 2009
1969 1978 1998 2001 2005 2010

Begins as M&S Offers company’s Introduces SmartPlant Acquires SmartPlant Introduces SmartPlant Acquires
Computing by first plant design Foundation, the first data Materials, now the Enterprise, the leading COADE
engineers working solution management system industry’s No. 1 materials solutions portfolio
on the Apollo specifically for the plant management solution
moon orbit industry; now more than
450 customers strong
2/14/2012 Proprietary & Confidential Information.

Intergraph Technology Portfolio
2/14/2012
Intergraph’s Portfolio & Data Interoperability Concept
Construction
3rd party Applications
BIZtalk Applications
Aspen Zyqad
Web Viewer
Adaptor Adaptor Adaptor Adaptor Adaptor Adaptor Adaptor Adaptor Adaptor
Process 3D/ Detailed Materials Plant

Process/ 2D Schematics
Simulation Design Manageme Visualization
nt
• Repository for documents & data
• Document & Data
Workflow Management
• Authorizations
Integration & Information Management • History / Versioning /
Document Application Engineering
Data Change Revision Control
Management Workflow
Management Integration Management
What is “Interoperability”?
 Definition of “Interoperability” (GCR 04-867)
 “…Interoperability is defined as the ability to manage and communicate

electronic product and project data between collaborating firms’ and within
individual companies’ design, construction, maintenance, and business
process systems..”
CONFIGURATION MANAGEMENT OF PLANT
ASSETS & DATA:
SETTING THE STAGE FOR INTEROPERABILITY
For New Builds and Legacy Operating Plants
People, Processes, Procedures, and Programs
Licensing Bases Plant Design Facility
22
2/14/2012 © 2012. Intergraph Corporation. All Rights Reserved. Proprietary & Confidential Information.
Licensing Bases Facility

Plant Design
23
2/14/2012 © 2012. Intergraph Corporation. All Rights Reserved.

Plant Design
CMIS
2/14/2012 24

Plant Design
CMIS
2/14/2012 Proprietary & Confidential
25 Information.
Licensing Bases Plant Design

Facility
CMIS
2/14/2012 Proprietary & Confidential
26 Information.
Configuration Management – The Traditional View
Approved Design Installed Facility Facility Operations

The Problem: Hierarchical Limits vs Molecular Reality
Data Sheet OEM DWG

FMEA
DATA Manual
SHEET OEM DWG
MFGR
Manual
DESIGN Number
PRESSURE
PUMP
MODEL eBOM
LOCATION
P/O
P&ID DWG Purchase
P&ID SERNO
Order
Most hierarchical Document Management Real information is massively inter-related

and PLM systems model their information and inter-dependent, and starting points
as represented by the familiar Cabinet → and navigation paths are unpredictable
Folder → File or Assembly → which does not lend itself to such neat, flat
Subassembly → Part paradigm. hierarchies
Information associated with a Tag has many dependencies
and inter-relationships
BOM: 24X89/P101
Supplier:
Des Op Press: 150psi
Simmons
Des Op Press: 100psi

Asset no:
Maint Proc: MM101
24X89
Manfr: Model:
Weir Tag: P-101
CP-C-4020
Purchase
Order:
U9735
Plant:
Texas2
Spec Document:
C056-KIV-1-DS-2001
System:
20 – Separation P&ID Drawing:
C056-SA-P-XR-2032-01
What did What

What
What we
we is
Whatdocumentation
What
What
canWho
dothe
need
buy plant’s
supports
…and
at
bewhich
are
did
we is so
the
its
we
need
obtained configuration
the
on
functional
at the
to
to licence
functional
capabilities
get itmaintain
from
fulfill the and
location safety
location
itneed Proprietary & Confidential Information.
Integrated CMIS Scope
CMIS
Scope

Integrated CMIS Benefits
 Single source of validated information

– Eliminates maintaining multiple databases and documents
– Reduces the amount of paperwork created and maintained
 Streamlined and ordered business processes
– Engineering
– Operations
– Maintenance
– Outage Planning and Preparation
 Impact analysis
– Impact of Changing Requirements
– Change Impact on Data and Documents
 Performance indicators of configuration control
 Basis for Margin Management and Plant Optimization processes

2/14/2012 © 2012. Intergraph Corporation. All Rights Reserved.
Interoperable CMIS Architecture in EPC Phase
SP Mat
CMIS
RMS
SPC
Validated
SPPID
ERP/EAM
Validation Zone
SPE
SPI
Other
2/14/2012 © 2012. Intergraph Corporation. All Rights Reserved. No Reuse without written Permission.
Configuration Management: A Lifecycle Approach
Project Award
A/E or NSSS Vendor Prime ContractorProject Turnover
Plant Operator
Reference Plant or Reactor Development Site Specific Project Generating Plant System
Load Data &
Documents from Load Other
Vendors,
SP3D MCAD & Load Data &
Contractors, etc
Other Other App Documents
Data For Prime
SPPID For O/O
For A/E Contractor
SPE or NSSS
Data Load
SPI
SP Nuclear Data Load SP Nuclear Handover SP Nuclear
SPEL CMIS ‘A’ CMIS ‘B’ CMIS ‘C’
Mat’l &
CMMS /
Construction ISI /
ITAAC EAM
Controls Tracking IST
Design Cert Inquiries & Inquiries &
Inquiries & Commitments Commitments
Commitments, with owner, with regulators,
with regulators regulators, others others
CMIS: A change-managed Change impact analysis & Requirements traceability

environment for validated data Performance indicators for configuration control
providing the basis for: Plant optimization and Margin Management
“CMIS” Architecture in Operations – Current Practice
CMIS
RMS
Validated
MMS

Interoperable CMIS Architecture in Operations
CMIS
RMS
Validated
Engg.
App1
Workflow-driven
Process
Engg. Validation Zone

App2 MMS
Engg.
App1
Other
Interoperable CMIS Architecture in Operations
CMIS
RMS
Validated
SPPID
Validation Zone
SPE
MMS
SPI
Other
SmartPlant for Operations
SmartPlant
Operations
Common Web Portal
Managing Change
DCS/
Integrated Project SPI SPEL SPPID SPL Reliability
Automation
Execution
Smart
SPRD I- Sketch
Sketch Safety Content
(SG&I) Management
Dynamic Design Basis
Interoperability Framework for
Modern Configuration Management
and Plant Asset Management
SP CMIS
Operational
Plant CM System
Inherent
Vendor Catalog
Controlled
Data, Procurement Model Change Mgt
Data, etc
Process
Design Basis Data, CM Functional Location,

Drawings, Equilibrium Asset Tag, etc.
Documents, etc SSC Asset
(Tags)
ITAAC & In-

Requirements
Service
Mgt &
Inspection
Traceability
Process
Inquiries &
Commitments
with regulators,
others
The Standard Nuclear Performance Model
Electricity
Production CAP
INPO 928
Operate Plant • Operate/Monitor S.S.C.

(INPO) • Monitor/Control Effluents
CORE PROCESSES • Monitor/Control Chemistry INPO 913
Configuration Work Management Equipment
Control (INPO) Reliability
SAP ECM (INPO) (INPO)
• Planning • Long Term Maint Plan

• Config Control
• Scheduling • ST’s
• Design Changes
• Preventive Maint • Perf & Reliability of S.S.C.
• Design Basis Changes
• Corrective Maint • Predictive Maint
• Fuel Management
• Decommissioning Plan
• Maint Non Plt Equip Procurement
• Plt Improve Maint
• Monitor Radiation Exposure Engineering
• Monitor Contamination
• Minor Maint
• Warehousing
SAP WCM Materials & • Inventory Mgmt
Services • Procure Mats & Svcs
(INPO) • Contractor Services
• Disposal & Surplusing SAP LSO
• Repairs, Returns & Svcs
SAP EH&S SAP PI
SAP EHS
Nuclear Fuel Support Services Loss Prevention Training
(NEI) (INPO/NEI) (NEI) (INPO)
• Provide & Transport Fuel • Information Services • Security Measures • Training Program
• Handle, Store, Dispose Fuel • Business Services • Perf Monitoring • Conduct Training
• Records & Docs Mgmt • Safety Measures • Attend Training
• Personnel Services • Licenses & Permits
Slide 39 • Maint Grounds & 766 • Emergency Planning
ENABLING PROCESSES • Support Comm & Govt • Fire Protection Proprietary & Confidential Information.
• Support Indust & Assoc No Reuse without written Permission.
BENEFITS OF INTEROPERABILITY
New Builds and Operating Plants

New Build Benefits
Åsgard
17,000 employees
Turnover US$14 billion
Operations 23 countries
The world’s largest floating
gas platform
“Sail-away could not
producing 12 billion cubic
have been achieved on
meters of gas / year
schedule without SPF
Change” 120,000 tagged items;
60,000 technical documents;
Approx. 8,000 changes;
5,500+ in follow-up
engineering
Change Management a
“mission critical” application
>500 users
during follow-on engineering
$4.5B Project
Engineering Change Management
 Benefits
– Improved change impact planning
– Improved change implementation
– Reduced costs
 Average cost of revising a drawing
from $700 to $80
– Overview of change and status
“Savings alone from this module justify the system

implementation”
Plant Commissioning
 Benefits
– Potential to reduce plant commissioning work by 10 - 20%*
– Potential to reduce OPEX by 10 - 20%*
*Coopers & Lybrand, 1997
“30 - 40% savings on total commissioning cost if able to

implement Plant Data Warehouse approach from the start
of a new plant”

U.S. Dept. of Energy - Savannah River Site Tritium Facility
 310 square miles on the

Savannah River, near Aiken, SC
 Built in the 1950s to produce
nuclear materials for national
defense
 Owned by the U.S. Department
of Energy and operated by
Washington Savannah River
Company
 10,000 employees

2/14/2012 © 2010. Intergraph Corporation. All Rights Reserved. 46
INTEROPERABILITY DEMONSTRATION
Intergraph SmartPlant CMIS Example
PwC Nuclear Template Example
What would an interoperable system look like?
SmartPlant Foundation Web Portal Microsoft Open Search

Similar to NetWeaver Approach Windows 7, SP Foundation
SmartPlant Foundation Web Portal Microsoft Silverlight Pivot

No 3D Model? No Problem – Laser Dynamic SP Foundation Queries
Scanning Integration is Economical
CONCLUSIONS: WHAT COMES NEXT?
Proposition for the Way Forward
Next Steps
 Decommissioning / Operating
– Prototyping activity
– Client participation, sponsorship
– Evaluate SAP Research activity for D&D
– Localization concerns wrt regulatory oversight, client plan, etc.
 New Builds
– Data handover / system turnover best practices, e.g. EPRI 2011 guideline
– CMIS strategy from earliest possible stages
– Plan for interoperability with other systems, e.g. Meridium
– Do you have a fully developed strategy? Now is the time!

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NPP Configuration Management across the Plant Life Cycle

SAP for Nuclear 2012

Keith Denton, Vice-President Global Power Industry, Intergraph

Proprietary & Confidential Information.

 Configuration Management across the Plant Life Cycle

– The Way Forward: Intergraph and SAP Interoperability

PwC Proprietary & Confidential Information.

– Pre-configured SAP content for NPP reference business processes

Three key drivers…

Proprietary & Confidential Information.

ENEL Slovenske Elektrarne nuclear plants

Kernkraftwerk Leibstadt (KKL) in Switzerland

Proprietary & Confidential Information.

PG&E PSEG Nuclear

Proprietary & Confidential Information.

Proprietary & Confidential Information.

Operate Plant • Operate/Monitor S.S.C.

• Planning • Long Term Maint Plan

Reliability Operations Engineering Construction SCM Maintenance

SCM Maintenance Operations Reliability Engineering

Drawings Pipe Design

Discipline Construction Notification Verify Step Clarify

Work Packages Questions Notify Initiator

In short, NPP’s are stuck in a 30+ year old paradigm

Old Way Way Forward

Data Sheet OEM DWG

Most hierarchical Document Management Real information is massively inter-related

Configuration Management - throughout the NPP lifecycle Engineering and

 Intergraph’s software is used by nearly all of the Fortune Global

1,500 people worldwide

Acquires SmartPlant® Releases

1980 1984 1999 2003 2009

1969 1978 1998 2001 2005 2010

2/14/2012 Proprietary & Confidential Information.

3rd party Applications

Process 3D/ Detailed Materials Plant

 Definition of “Interoperability” (GCR 04-867)

 “…Interoperability is defined as the ability to manage and communicate

Licensing Bases Plant Design Facility

Licensing Bases Facility

Licensing Bases Facility

Licensing Bases Facility

Licensing Bases Plant Design

Approved Design Installed Facility Facility Operations

2/14/2012 Proprietary & Confidential Information.

Data Sheet OEM DWG

Most hierarchical Document Management Real information is massively inter-related

Des Op Press: 100psi

What did What

2/14/2012 Proprietary & Confidential Information.

 Single source of validated information

Proprietary & Confidential Information.

CMIS: A change-managed Change impact analysis & Requirements traceability

2/14/2012 Proprietary & Confidential Information.

Engg. Validation Zone

Design Basis Data, CM Functional Location,

ITAAC & In-

Operate Plant • Operate/Monitor S.S.C.

• Planning • Long Term Maint Plan

© 2012. Intergraph Corporation. All Rights Reserved.

“Savings alone from this module justify the system

*Coopers & Lybrand, 1997

“30 - 40% savings on total commissioning cost if able to