Nuclear Certification (NQA) of CAESAR II

Mandeep Singh (Author, Presenter) Richard Ay, Kathleen Byle (Contributors) Intergraph
Version Date: 04.09.13

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Agenda
1. Introduction and use of CAESAR II in the power Industry 2. Addressing the Requirements of the Nuclear Market
ASME NQA-1 US 10 CFR Part 50 App. B, US 10 CFR Part 21

3. CAESAR IIs approach to NQA-1 Qualification (CGD, Design Control and Test Control) 4. CAESAR II interfaces and a Case Study 5. Q&A
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What is CAESAR II - an Industry Standard

One of the first commercial, PC-based, pipe stress design and analysis program, and growing ever since 1984 Most comprehensive range of capabilities both static and dynamic analysis Extensive component/system modeling capabilities can address most piping situations Stress evaluation in accordance with 30+ international piping codes which promotes its use in over 80 countries Known for its technical superiority, flexibility, ease of use, and innovation Interfaces to design, S3D, CADWorx, PDS Pedigree that is vital in the nuclear industry.
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CAESAR II Nuclear Addressing the Nuclear Market Needs

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CAESAR II NQA-1 Program Overview

Program Compliant with applicable Requirements of ASME NQA-1 2008/2009 ASME NQA-1
Commercial Grade Dedication (CGD) completed Internal Document Control and Record Center Established

10 CFR Part 50 Appendix B Program

Error Reporting in place Accessible to customers via SharePoint login

10 CFR Part 21 Procedure Approved

10 CFR Part 21 Compliance officer on site

On-staff: Kathleen Byle, NQA lead auditor and contributing author to recent edition of ASME NQA-1 std. with CGD guidance
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CAESAR II Approach to NQA-1 Qualification CGD Design Control Test Control

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Commercial Grade Dedication (CGD)

CGD to bring legacy CAESAR II development (pre-2011) up to NQA standard. Approaches used from ASME NQA-1 2012 edition to perform CGD: Method 1: Inspections, tests, or analyses performed after delivery
Detailed Technical verification by alternate calculation (Mathcad) Comparison to published benchmarks (NRC benchmarks) Tests developed are added to the existing test suite to be run every release. Provides adequate, repeatable and documented test coverage of software.

Method 4: Acceptable supplier/item performance record

Reliability demonstrated by successful track record (in use since 1984 and defacto std. in commercial applications)

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CGD CAESAR II Effort Numerical Focus

Covered by NQA program for new development since 2011

Focus of CGD & Part 21 Problem reporting

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Pipe Codes NQA Qualified via CGD

Locale Pipe Code
ASME B31.1 ASME B31.3 ASME B31.4 & B31.4 Chapter IX ASME B31.5 ASME B31.8 & Chapter VIII ASME B31.9 ASME B31.11 ASME SECT III CLASS 2 ASME SECT III CLASS 3 U.S. Navy 505 ANSI B31.1 1967 GPTC/Z380 FBDR Z662 & Z662 Chapter 11 Stoomwezen Swedish Method 1 & 2 BS-806 UKOOA BS-7159 IGE/TD/12 PD 8010 Part 1 & 2 CODETI RCC-M C RCC-M D JPI HPGSL TBK 5-6 DnV EN-13480 ISO-14692
X X X X X X X X X X X X X X X X X X X

Power
X

Industry Category Process Pipeline Offshore Nuclear

X X X X X X

FRP

USA

X X X X X X X X X X

Germany Canada Netherlands Sweden

UK

France Japan Norway International 4th June 2013

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Full Scope of Commercial Grade Dedication at this time

Static Solver Dynamic Solver Piping Codes Implementation ASME B31.1 & ASME B31.3 ASME NC & ASME ND RCCM C & RCCM D Configuration Options

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Details of Technical CII Features Targeted by CGD

Add F/A in Stresses Include Insulation in Hydrotest Add Torsion in SL Stresses All Cases Corroded Allow Users SIF on Bends Base Hoop Stress On Use PD/4t Welding Contour Tees B31.3 Sec319.2.3c B31.3 Sustained SIF Multiplier Include Pressure Stiffening on Bends B31.3 Appendix P B31.3 Code Case 178 No RFT/WLT in Reduced Fitting SIFs Use WRC329 Ignore B31.1/B31.3 Wc Factor Thermal Bowing Delta Temperature Liberal Stress Allowable

These critical functions mapped to test cases and qualified using alternate calculations.

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CGD Verification sample

Also available for purchase

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Design Control: Mapping Requirements to Tests

All development follows Intergraph CAESAR II NQA Program Requirement and Design Control Process
Feature Described Acceptance Criteria Defined Tests Planned (Unit and Acceptance) Multiple level of reviews (Technical, Quality, Management)

Traceability of Software Development Life-Cycle

Design plan to source code to testing Internal source code comments trace back to design, Test Cases trace back to feature

Designs and implementation reviewed on acceptance criteria.

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Input Verification Feature in CAESAR II Nuclear

Input can be verified via a text file. Enables the nuclear user to provide records for Design Control. No Dependence on GUI

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Test Control Map Functionality of CAESAR II

Being an Analysis software, numerical correctness is paramount. Functionality of the software is complete for CGD and numerical content Testing:
550+ automated tests for numerical accuracy Additional 400+ tests for user interface and workflow Test coverage metrics used to manage release plans

Continuous improvements
more Automated tests, targeted testing and wider coverage Complete automated builds, from build to installation to testing

Following Agile development with short incremental development cycles, more intermediate builds & automated testing - to catch issues early

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Tracking Released Software issues

Intergraph support standard practice
User feedback channeled directly into development processes User notifications regarding related status updates issued throughout development Software release criteria based on issue review and prioritization

Intergraph PPM defect priority guidelines

P1 - Vital P2 - Crucial P3 - High P4 - Normal

Enhanced support for CAESAR II Nuclear customers

US 10 CFR Part 50 Appendix B error reporting available via a SharePoint portal US 10 CFR Part 21 (NRC reporting) also in place

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CAESAR II Interfaces Using CII in the Nuclear Industry interfaces and Case Study

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Smart 3D - CAESAR II Interface

1. 2.

Enhanced & interactive Smart 3D-CAESAR II interface Results exported back to SPR/Smart 3D

SP Review Smart or 3D Smart 3D

CAESAR II

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The new Smart 3D-CAESAR II interface will greatly reduce our modeling work load and allow a smooth data transfer from the design to the engineering environment Mustafa mercik, Pipe stress analyst. Intergraph Confidential Linde AG

Reduce errors by getting design context in CAESAR II

Engineer Reduces time and error in modeling Get design context to make intelligent changes within stress model Designer Easy view of changes made by engineer within the design model Support and Structural engineers Get loads from piping with location in easy to review format (SPR or S3D) Quality Assurance* Compare design and stress model to ensure change compliance
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Some CAESAR II Interfaces to support your workflow

CAD interfaces
Smart 3D, CADWorx, PDS, CADPIPE and PCF

Hydraulic interfaces
AFT, PIPENET, LIQT, Pipeplus, FlowMaster

CAESAR II Neutral file text file interface

many 3rd parties

CAESAR II Access MDB file

Smart 3D, Lisega (support design), .

CAESAR II FEA interface coming very soon more.

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Drivers of Success Runners-up, CAU 2012

GENPRO Engenharia S.A., Brazil
Designed and Built a Nuclear Research Reactor plant in Brazil (800 lines of nuclear classes 2,3 and non-nuclear piping) with CAESAR II CAESAR II benefits for GENPRO
Performed seismic analysis of piping using spectrum specified at multiple levels Eliminated snubbers which eliminated maintenance costs Verified equipment nozzles to meet requirements

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CAESAR II Nuclear Release Candidate Q3 2013

Developed to ASME NQA-1 Std. subject to 10 CFR Part 50 App. B & 10 CFR Part 21
Commercial grade dedication to bring legacy development (1984-now) to NQA-1 Std. Internal audits provide continuous quality evaluation & improvement New text file for input verification 550+ automated and 400+ manual tests Updated V&V Manual with software for users to benchmark their installation Premium technical direct support from Intergraph Support for audits conducted on behalf of CAESAR II Nuclear customers. Option to purchase CAESAR II Commercial Grade Dedication (CGD) Verification Guide

NQA - a Standard of Quality focusing on preventing defects before release

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Ready to address user needs in Nuclear industry

Thank You! Questions?

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