EDF Nuclear New Build Hinkley Point C Embedding Orbit™ onto Project

Background

Hinkley Point C by EDF represents the first new nuclear power station to be built in the UK since Sizewell B in almost 25 years. EDF requested that OCCMS undertake a full audit of existing completions and handover processes, handover documentation and contractual expectations from both EDF and all sub-contractors. This included:

  • Identifying systems and processes currently in use and provide recommendations on alignment, process improvements and key documentation requirements.
  • Creation and proposal of an implementation plan to deploy a modern completions management system (CMS) for the project.

After the initial review and audit of HPC capabilities with regard to Completions, OCCMS were given the contract by EDF to deploy the Orbit Completions System and a Completions Subject Matter Expert to provide completions guidance and expertise for the Main Civils Work Scope.

The Challenge

The challenges for introducing a Completions System and Process to HPC at this stage were as follows:

  • OCCMS were asked to apply completions to just the Civils part of the work at site. A separate Orbit database was used to manage the completions of the MEH JV scope. However, a gap was identified between the extent of these two aspects of HPC for example the GE and Framatome scope.
  • HPC Civils work scope was already well established at site and there were some complications in applying a new process at this stage of such a major project.
  • The use of documents instead of checksheets resulted in the focus of Orbit being shifted to the review and status of documents as released to the HPC Document Control System Teamcenter.
  • Integrations needed to be set up between two separate systems:
  • CCIS – this holds the latest Non-Conformance Report (NCR) and Field Change Request (FCR) scope however the scope had not been clearly allocated to its respective End of Construction report (ECR)
  • Teamcenter – this is the document control system through which all quality records are issued for approval by the contractors, again not clearly identifiable which record belonged to which ECR scope
  • The existing ‘Handover’ Team at site was put together based on civils experience and there was little completions knowledge across the team members
  • The Tier 1 Contractors were using separate ‘List of Deliverables’ (LOD) spreadsheets to provide information on the status of their quality records. This disparate information needed to be brought into Orbit and kept updated.
  • There was little or no common thread through the work scope to tie the various platforms together. EDF had introduced a document to manage the functional identification of build objects but this had not been applied uniformly through the civils scope of work.
  • In order to introduce a new ‘IT Solution’ we had to adhere to a strict governance process which became almost a project in itself. This slowed the introduction of Orbit and took time that could have been used more productively to populate and implement completions.

The Solution

Based on the key findings from the audit, combined with discovery made once the governance and phased steps of the Orbit introduction were undertaken the following activities and solutions were introduced:

  • The flexibility of the Orbit system enabled us to tailor the usual completion structure to match the structure that was being implemented through site.
  • Orbit also enabled the creation of specific electronic check sheets tailored to the Civils Inspection and Test Plans (ITPs) and enabled the facility, using Orbit’s Advanced Work Packaging feature, to bring together any elements of the scope of work and create a bespoke completions and handover package.
  • The completions structure was modelled on the ‘Partitioning Strategy’ provided by the New Nuclear Build (NNB) team and the Tier 1 Contractors, as follows:
    • Unit ID = Contract Number
    • System = Grand Parent End of Construction Report (G-ECR)
    • Sub System = Parent End of Construction Report (P-ECR)
    • Tag = Child End of Construction Report (C-ECR)

  • Orbit’s ‘localisation’ feature allowed replacement of nomenclature to align project terminology
  • The document review cycle was managed in Teamcenter therefore Orbit had to be adaptable enough to be able to integrate with this system to receive ‘live’ updates on the status of the quality documents. This was achieved by Teamcenter feeding this data directly into the Orbit database using the Orbit API, first as a bulk load then ‘live’ updates at regular intervals
  • OCCMS development team worked with Mulesoft integration team to further develop the API to map the relevant TC document fields to Orbit’s native fields
  • New data fields were introduced to Orbit to enable the completions team to add further information to documents once in the Orbit database for tracking and handover requirements
  • Custom reports were added to provide the completions team with greater visibility of project completions from within Orbit
  • A supplementary team was provided to integrate with the existing team to review and capture the backlog of completed handovers and exception items.
  • The NCR and FCR raised as part of the management of change were held within the ‘CCIS’ system. This system did not relate the NCR/FCR to the specific scope it affected. By sending data to Orbit’s API, a common value could be allocated to import the NCR/FCR into Orbit from whence it could then be allocated to its respective ECR.
  • The NNB team and each of the Tier 1 contractors used their own systems to control and track any punch list and exception items. Bringing these together in Orbit was an important step in visualizing the outstanding scope and managing its completion.
  • The tag detail area in Orbit allowed us to bring together the status of all the elements that needed to be tracked in order to provide the most up to date information on the status of completion for the scope associated with the production of the End of Construction Status Reports.
  • Using the Advanced Work Packaging facility in Civils Orbit we will group the completed civils scope to facilitate the completion of areas, levels and rooms in preparation for installation of equipment, cables and pipework by MEH JV.

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