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June 2013 Intergraph Confidential

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Nuclear Certification (NQA) of CAESAR IIMandeep Singh (Author, Presenter)

Richard Ay, Kathleen Byle (Contributors)

IntergraphVersion 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, andgrowing ever since 1984

Most comprehensive range of capabilities both static and dynamic analysis

Extensive component/system modeling

capabilities can address most pipingsituations

Stress evaluation in accordance with 30+international piping codes which promotes itsuse 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.3

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CAESAR II NuclearAddressing 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 QualificationCGD

Design ControlTest 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 de-

facto std. in commercial applications)

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CGD CAESAR II Effort Numerical Focus

Covered byNQA program

for newdevelopmentsince 2011

Focus ofCGD&

Part 21Problemreporting

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Pipe Codes NQA Qualified via CGD

Industry Category

Locale Pipe Code Power Process Pipeline Offshore Nuclear FRP

USA

ASME B31.1 XASME B31.3 XASME B31.4 & B31.4 Chapter IX X XASME B31.5 XASME B31.8 & Chapter VIII X XASME B31.9 XASME B31.11 XASME SECT III CLASS 2 XASME SECT III CLASS 3 XU.S. Navy 505 XANSI B31.1 1967 XGPTC/Z380 X

Germany FBDR XCanada Z662 & Z662 Chapter 11 X X

Netherlands Stoomwezen XSweden Swedish Method 1 & 2 X

UKBS-806 XUKOOA XBS-7159 XIGE/TD/12

X

PD 8010 Part 1 & 2 X X

France CODETI X XRCC-M C XRCC-M D X

Japan JPI XHPGSL X

Norway TBK 5-6 XDnV X

International EN-13480 X XISO-14692 X 9

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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 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

Details of Technical CII Features

Targeted by CGD

These critical functions mapped

to test cases and qualif ied usingalternate 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 recordsfor 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 InterfacesUsing CII in the Nuclear Industry

interfaces and Case Study

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Smart 3D - CAESAR II Interface

1. Enhanced & interactive Smart 3D-CAESAR II interface2. Results exported back to SPR/Smart 3D

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. Linde AG

Smart 3DCAESAR II

SP Review or Smart 3D

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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 thedesign model

Support and Structural engineers

Get loads from piping with location in easy to reviewformat (SPR or S3D)

Quality Assurance*

Compare design and stress model to ensure changecompliance

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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 ofnuclear 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 IINuclear customers.

Option to purchase CAESAR II Commercial GradeDedication (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

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