1. New Plant Configuration Management Development and Implementation Process
John Maciejewski INPO
I am John Maciejewski
Over the past 20 years at INPO I have been involved in the formation of AP-929 as well as development of evaluation related CM and margin management concepts at INPO.
I always enjoy talking to this group because you are the advocates of CM. The importance of CM hit home to me early in my career when we were trying to design and install temporary systems at TMI to maintain control immediately after the TMI-2 accident without accurate configuration information. That meant having people entering highly contaminated radiation areas to gather as-built information and making informed guesses.
INPO with the help of an industry task group made up of individuals involved in new plant projects developed a new CM document for use during new plant development and deployment. It also develops a foundation for operational CM.
Status: We’ve been working on it for about 2 years and it is in final INPO management concurrence. As with many original INPO documents it will be issued as a preliminary document to gather feedback as it is used.

2. New Plant Configuration Management Development and Implementation Process
Issued AP-932 “New Plant Configuration Management Development and Implementation Process” in November 2009 as Preliminary
Process document that provides flexibility in how to implement

3. Plan to issue AP-932 as final in 2010
New Plant Configuration Management Development and Implementation Process
Plan to issue AP-932 as final in 2010
Plan to expand AP-932 to cover CM during operation considering :
The 3-D model
Computer technology
AP-929

4. Reasons for development:
New Plant Configuration Management Development and Implementation Process
Reasons for development:
INPO AP-929 developed based on modifications/changes to an existing plant
Extensive use of computer technology for new plant deployment
Benchmarking international projects revealed significant use of computer technology in providing CM
Recommendations from several CNO’s
Use by other industries of relational databases to control information
Some of the considerations that went into deciding to develop the new document were the following:
929 wasn’t written from a CM development perspective (develop CM during deployment, not backfit)
INPO design review visits to EPCs revealed this (document incorporates use of computer technology)
Benchmarking in Japan, Korea, Europe (computer technology used extensively)
Several CNO’s recognize the importance of starting and developing CM during NPD as well as the importance of using computer technology for CM.
Significant use of computer for information and configuration management (NASA, Bowing, Auto makers, government)

5. New Plant Configuration Management Development and Implementation Process
Document sections:
Configuration management program attributes
Process description is for new plant deployment (not operation)
Includes incorporating information needed for operation and a description of linking information using relational databases
The document has basically two main sections (they incorporate the use of computer technology):
Attributes: we started over 2 years ago with a listing of attributes for CM in general. (some of you may remember this). It was in part based on work you had already done. We retained some of this and added additional programmatic attributes based on industry standards.
Process description: this is for plant deployment (not for an operating plant)
It relies on computer technology
Use of a 3-D model and relational databases for CM
Foundation for operational CM
Linkage: Example of linking information using the component designator as the common relationship

6. New Plant Configuration Management Development and Implementation Process
Concepts
CM development starts early in the design phase
Design is essentially complete prior to construction
Computer technology is used extensively in design ( 3-D model, data bases)
Computer technology supports development of a detailed design that can be built.
The plant is built as designed. Changes are only made because of errors in design.
You will find woven in the document the following basic concepts for new plant construction and CM success. These concepts are derived from our benchmarking trips internationally and in the US as well as input from other industries (Space, Airline)
The document relies on these concepts to avoid the CM problems we had with our first generation of plants. As you are aware CM problems led to and kept a number of plants down for extended periods of time.
EPC & owner must interface early (The owner must tell the EPC what is desired. What will be needed for operation?)
Clear message for proven success (time and economic pressures can undermine this e.g., LES, enrichment facility project in New Mexico).
Being done today.
Interference checks using the 3-D model
Must have this discipline. Hard for people to think this way.

7. CM attributes for pre-commercial operation
New Plant Configuration Management Development and Implementation Process
CM attributes for pre-commercial operation
A listing of CM attributes for design and construction that will enable establishment of effective CM
The attributes include basic CM program attributes from industry standards plus :
Incorporates 3-D model
Includes information types for CM
Formality of Information Exchange among organizations and common templates (equipment specs, SDs)
Ensures foundation for operational CM is developed
We had many comments on what attributes to list and not to list. We decided on the ones we thought pertain most to the document.

8. New Plant Configuration Management Development and Implementation Process
Process elements:
Determine CM scope and information
Establish an electronic platform and standard format
Electronically link related information
Enter information into the computer
Produce information for construction
Build the plant per the design (correct errors only)
Turnover the computer databases and physical plant to COL holder
Process Elements:
(These basic and other supporting elements are shown in a flow chart)
CM scope:
Design required for operation
Establish boundaries with non-plant operation facilities
Extent of information within CM scope (include design information ) (how far do you go? Controlled documents in existing plants?)
Helps in information transfer and turnover (Interface early with EPC.)
Key (links to design information) use relational databases.
Concept: with appropriate links enter information once (avoid duplication or omission errors)
Produce information for construction (computer screens or printouts. Don’t think in terms of paper any more.)
Must build per design (correct errors only) 3-D model makes this possible.
Turn over for operational CM (Always keep this in mind during new plant deployment. What will you need for operational CM. This relates back to CM scope and information within the scope.)

9. Using the component designator as the common relationship
New Plant Configuration Management Development and Implementation Process
Using the component designator as the common relationship
Using a common electronic platform/framework, design information can be linked electronically to the related components and other related information using the component designator.
For example the component designator (e. g., MOV-XX) is the common relationship for relating information.
Design information and information based on design information should be linked.
Example provided in document to show concept of computer linkages of information
Component designator used as the common relationship because we typically relate at the component level (pump, valve, breaker, transformer, level indicator, heat exchanger)
Linking to design information is key.

10. New Plant Configuration Management Development and Implementation Process
SUMMARY
INPO issued AP-932 “New Plant Configuration Management Development and Implementation Process” in November 2009
Concepts are based on CM lessons learned and recent benchmarking
Incorporates computer technology as a tool for CM
Plan to issue AP-932 final in 2010
Plan to expand AP-932 to cover CM during operation