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Cheryl Brackett, Lead Work Package Engineer, Cianbro Constructors Eric Crivella, Plant Construction Executive, Bentley Systems, Inc.

•  Create $10 million, state-of-the-art Eastern Manufacturing Facility.

•  Build and ship 54 prefabricated modules, totaling 9,000 tons of steel and 200,000 lineal feet of pipe.

•  The modules average 40-feet-by-40-feet in cross section, about 120-feet long, and weigh up to 700 tons each.

•  ConstructSim to visualize and interpret the module, plan construction, and generate parts lists and other information

Construction Work Areas

Materials Management

Track Spools Track Modules Work Complete

Location

Expedite Install Work to Ready a System for

Testing

Expediting Reports •  Dwgs Not Released •  Spools Not Fab •  Field Mat’ls Not Onsite

Work Packs

Test Packs

Turnover Systems

Priorities

Feasibility Study

Issued

Shop Fab Work Pack Reports •  Spool List •  Field Matl Issue •  Steel Hang List •  Jobcards

Priorities

System Reports

Pressure Test Record Systems Completion

Cianbro

Bentley

Jacobs

•  PDS 3D CAD •  Module definition & tracking •  Isometrics •  ISO transmittal database •  Line List •  Equipment list •  CIS/2 & piecemark •  Fabrication status •  iTrack on-site & progress •  Pipe unit rates •  IMS QA/QC and weld tracking

The VPM is distributed into a shared workgroup environment.

A “Master Copy” of the VPM is archived on a server, with local copies resident on the user and data processing machines.

User Machine #1

User Machine #2

Uses

User Machine #3

•  3D Visualization, Interactive Planning & Construction Sequencing

•  WorkFace Planning –  Steel and Pipe (fab, install & hydro) Work Packs

•  Material & Constraint Analysis •  Rapid Queries •  Status Tracking & Progressing •  Crane Logistics planning •  Quality Assurance

•  Spool fabrication •  Equipment installation •  ISO release status •  Pipe material availability •  Work step tracking •  Test pack status •  QA/QC status •  Work package constraints

•  Top down management support and bottom up buy in from field supervision is key

•  Don’t underestimate the systems integration effort and the learning curve involved –  Start as early in the project as possible

•  VPM Admin role is critical –  Always train a backup Admin

•  Data validation is always a problem

•  Changing people & work processes is hard!

•  Improved constructability analysis, interactive planning and coordination between engineering office and site office in using Virtual Plant Model

•  Visually plan optimal steel and pipe work crew packages

•  Streamline material, equipment & sequencing

•  Reduce rework / out-of sequence work

•  Speed time to start-up by systems tracking

•  Automated task estimates / automate data entry

•  Reduce time looking for information via visual monitoring the status of engineering, materials and construction execution progress

•  Had direct comparison data because CIS/2 data was not available for 3 modules •  Steel MTOs – substantially reduced time and human

error (shin plates and bolts often get overlooked) •  CSim steel work pack in 4 hours; to do same work

pack manually would require 40+ hours

•  CSim saved a ton of time, effort and money on the structural steel

•  Bottom Line on the Business Case: •  ConstructSim saved Cianbro ~$7M and helped

ensure the project Key Performance Indicators of cost, schedule, safety and quality were met!!

Eric Crivella

Plant Construction Executive

Bentley Systems

+1 713 249 4407

[email protected]

If you would like more information contact:

Cheryl Brackett

Lead Work Package Engineer

Cianbro Constructors

+ 1 207 907 7405

[email protected]